Aerosol delivery device including a bubble jet head and related method

ABSTRACT

Aerosol delivery devices including mechanisms configured to deliver an aerosol precursor composition from a reservoir to an atomizer including a vaporization heating element to produce a vapor are disclosed. For example, a bubble jet head may be configured to dispense the aerosol precursor composition to the atomizer. The bubble jet head may be fixedly coupled to the atomizer. The bubble jet head may include a precursor inlet, an ejection heating element, and a precursor nozzle. The atomizer may include a vaporization heating element.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.14/524,778, filed Oct. 27, 2014, which claims the benefit of U.S.Provisional Application No. 61/897,917; filed Oct. 31, 2013, which isincorporated herein by reference in its entirety which applications arehereby incorporated by reference in their entirety in this application.

FIELD OF THE DISCLOSURE

The present disclosure relates to aerosol delivery devices, such assmoking articles; and more particularly, to aerosol delivery devicesthat utilize electrically generated heat for the production of aerosol(e.g., smoking articles commonly referred to as electronic cigarettes).Aerosol delivery devices including mechanisms for delivery of an aerosolprecursor composition to an atomizer are provided. The smoking articlesmay be configured to heat an aerosol precursor, which incorporatesmaterials made or derived from tobacco or otherwise incorporate tobacco,capable of vaporizing to form an inhalable aerosol for humanconsumption.

BACKGROUND

Many smoking devices have been proposed through the years asimprovements upon, or alternatives to, smoking products that requirecombusting tobacco for use. Many of those devices purportedly have beendesigned to provide the sensations associated with cigarette, cigar, orpipe smoking, but without delivering considerable quantities ofincomplete combustion and pyrolysis products that result from theburning of tobacco. To this end, there have been proposed numeroussmoking products, flavor generators, and medicinal inhalers that utilizeelectrical energy to vaporize or heat a volatile material, or attempt toprovide the sensations of cigarette, cigar, or pipe smoking withoutburning tobacco to a significant degree. See, for example, the variousalternative smoking articles, aerosol delivery devices and heatgenerating sources set forth in the background art described in U.S.Pat. No. 7,726,320 to Robinson et al. and U.S. Pat. Pub. Nos.2013/0255702 to Griffith, Jr. et al. and 2014/0096781 to Sears et al.,which are incorporated herein by reference. See also, for example, thevarious types of smoking articles, aerosol delivery devices andelectrically powered heat generating sources referenced by brand nameand commercial source in U.S. patent application Ser. No. 14/170,838,filed Feb. 3, 2014, to Bless et al., which is incorporated herein byreference.

However, it may be desirable to provide aerosol delivery devices withenhanced functionality. In this regard, it may be desirable to improvedelivery of an aerosol precursor composition to an atomizer.

BRIEF SUMMARY OF THE DISCLOSURE

The present disclosure relates to aerosol delivery systems. Such systemshave the ability to generate aerosol as a result of heat generated byelectrical power sources, and to deliver aerosol that is intended to bedrawn into the mouth of a user. Of particular interest are aerosoldelivery systems that provide components of tobacco in an aerosol form,such as is provided to smokers by devices commonly known orcharacterized as electronic cigarettes. As used herein, the term“aerosol” is meant to include vapors, gases and aerosols of a form ortype suitable for human inhalation, whether or not visible, and whetheror not of a form that might be considered to be “smoke-like.”

Various embodiments of mechanisms for delivering an aerosol precursorcomposition to an atomizer are provided. These mechanisms may includebubble jet heads, as described hereinafter. As described herein, abubble jet head is a component configured to heat a fluid (e.g., anaerosol precursor composition) to produce a bubble of vapor that appliespressure to the fluid and ejects one or more droplets of the fluidtherefrom. Bubble jet heads may be defined as including an inlet (e.g.,a precursor inlet), an ejection heating element, and a nozzle (e.g., aprecursor nozzle), which may be housed within, or defined by, a wafer,substrate, or housing.

In one aspect an aerosol delivery device is provided. The aerosoldelivery device may include a reservoir at least partially filled withan aerosol precursor composition. Further, the aerosol delivery devicemay include a bubble jet head in fluid communication with the reservoir.The bubble jet head may be configured to dispense the aerosol precursorcomposition from the reservoir. Additionally, the aerosol deliverydevice may include an atomizer configured to heat the aerosol precursorcomposition dispensed by the bubble jet head to produce an aerosol. Thebubble jet head and the atomizer may be fixedly coupled to one another.

In some embodiments the aerosol delivery device may further include anouter body and a housing received within the outer body. The bubble jethead and the atomizer may be fixedly coupled to one another via thehousing. The bubble jet head may be coupled to the atomizer via one ormore spacers. Further, the bubble jet head and the atomizer may beelectrically coupled via a flexible circuit.

In some embodiments the atomizer may include a housing, a vaporizationheating element coupled to the housing, and a reinforcement membercoupled to and configured to support the housing. The reinforcementmember may define a cutout. The aerosol delivery device may additionallyinclude an outer body, wherein a heating surface of the atomizer isoriented at a non-zero angle with respect to a longitudinal axis of theouter body.

In some embodiments the aerosol delivery device may include an outerbody. A heating surface of the atomizer may be oriented substantiallyparallel to a longitudinal axis of the outer body. The bubble jet headmay be configured to eject the aerosol precursor compositionsubstantially perpendicularly to a heating surface of the atomizer. Aheating surface of the atomizer may be non-planar. The heating surfaceof the atomizer may be substantially conical. A heating surface of theatomizer may be textured.

In some embodiments the reservoir may include a reservoir substrateconfigured to direct the aerosol precursor composition to the bubble jethead. The bubble jet head may be coupled to a distal end of thereservoir. The bubble jet head may be coupled to a lateral side of thereservoir. The bubble jet head and the atomizer may be positionedbetween the reservoir and a mouthpiece. Alternatively, the reservoir maybe positioned between a mouthpiece and the atomizer and the bubble jethead. The aerosol delivery device may further include a cartridgecomprising a base and a control body comprising a coupler. The base maybe configured to engage the coupler to provide a mechanical andelectrical connection between the cartridge and the control body.

In an additional aspect a combined dispenser and atomizer assembly isprovided. The combined dispenser and atomizer assembly may include ahousing, a bubble jet head including an ejection heating elementconfigured to dispense an aerosol precursor composition from areservoir, and an atomizer including a vaporization heating elementconfigured to heat the aerosol precursor composition dispensed by thebubble jet head to produce an aerosol. The bubble jet head and theatomizer may be coupled to one another via the housing. The housing maybe configured for receipt within an outer body of an aerosol deliverydevice.

In some embodiments the bubble jet head may further include a precursorinlet and a precursor nozzle. The atomizer may further include anaerosol outlet. An area of the aerosol outlet may be greater than anarea of the precursor nozzle. A thermal mass of the ejection heatingelement may be less than a thermal mass of the vaporization heatingelement. The ejection heating element, the precursor nozzle, and thevaporization heating element may be axially aligned. The housing maydefine at least one of the precursor inlet, the precursor nozzle, andthe aerosol outlet.

In an additional aspect, an aerosol delivery device is provided. Theaerosol delivery device may include a reservoir at least partiallyfilled with an aerosol precursor composition. Further, the aerosoldelivery device may include a housing including a precursor inlet influid communication with the reservoir, an ejection heating element, anda precursor nozzle. The ejection heating element may be configured toeject the aerosol precursor composition received through the precursorinlet out through the precursor nozzle. Additionally, the aerosoldelivery device may include an atomizer configured to heat the aerosolprecursor composition dispensed from the housing to produce an aerosol.The ejection heating element and the atomizer may be fixedly coupled toone another.

In some embodiments the atomizer may be received within the housing, andthe housing and the reservoir may be received within an outer body. Inanother embodiment the housing may be coupled to the atomizer via one ormore spacers. The housing and the atomizer may be electrically coupledvia a flexible circuit.

In some embodiments the atomizer may include an atomizer housing, avaporization heating element coupled to the housing, and a reinforcementmember coupled to and configured to support the housing. Thereinforcement member may define a cutout. The aerosol delivery devicemay additionally include an outer body, and a heating surface of theatomizer may be oriented at a non-zero angle with respect to alongitudinal axis of the outer body. In another embodiment the heatingsurface of the atomizer may be oriented substantially parallel to alongitudinal axis of the outer body.

In some embodiments the precursor nozzle may be configured to eject theaerosol precursor composition substantially perpendicularly to a heatingsurface of the atomizer. The heating surface of the atomizer may benon-planar. The heating surface of the atomizer may be substantiallyconical. The heating surface of the atomizer may be textured.

In some embodiments the reservoir may include a reservoir substrateconfigured to direct the aerosol precursor composition to the precursorinlet. The housing may be coupled to a distal end of the reservoir. Inanother embodiment the housing may be coupled to a lateral side of thereservoir. The housing and the atomizer may be positioned between thereservoir and a mouthpiece. In another embodiment the reservoir may bepositioned between a mouthpiece and the atomizer and the housing. Theaerosol delivery device may additionally include a cartridge including abase, and a control body including a coupler. The base may be configuredto engage the coupler to provide a mechanical and electrical connectionbetween the cartridge and the control body.

In an additional aspect a combined dispenser and atomizer assembly isprovided. The combined dispenser and atomizer assembly may include ahousing, an ejection heating element configured to dispense an aerosolprecursor composition from a reservoir, and a vaporization heatingelement configured to heat the aerosol precursor composition dispensedby the ejection heating element to produce an aerosol. The ejectionheating element and the vaporization heating element may be receivedwithin the housing, and the housing may be configured for receipt withinan outer body of an aerosol delivery device.

In some embodiments the combined dispenser and atomizer assembly mayadditionally include a precursor inlet, a precursor nozzle, avaporization heating element and an aerosol outlet. An area of theaerosol outlet may be greater than an area of the precursor nozzle. Athermal mass of the ejection heating element may be less than a thermalmass of the vaporization heating element. The ejection heating element,the precursor nozzle, and the vaporization heating element may beaxially aligned. The housing may define at least one of the precursorinlet, the precursor nozzle, and the aerosol outlet.

In an additional aspect a method for aerosolization in an aerosoldelivery device is provided. The method may include directing an airflowfrom a control body including a power source through a cartridgeincluding a reservoir. The method may additionally include dispensing anaerosol precursor composition from the reservoir via a precursor inlet,an ejection heating element, and a precursor nozzle. The method mayfurther include heating (e.g., vaporizing) the aerosol precursorcomposition dispensed from the reservoir with an atomizer.

In some embodiments dispensing the aerosol precursor composition andheating the aerosol precursor composition may include independentlyapplying power from the power source to the ejection heating element andthe atomizer. Dispensing the aerosol precursor composition and heatingthe aerosol precursor composition may include directing power to theatomizer after applying power to the ejection heating element. Themethod may additionally include preheating the aerosol precursorcomposition with the ejection heating element prior to dispensing theaerosol precursor composition. Further, the method may include detectinga temperature of the aerosol precursor composition, wherein preheatingthe aerosol precursor composition includes preheating the aerosolprecursor composition to a desired temperature. Preheating the aerosolprecursor composition may include applying a relatively smaller pulsewidth or pulse amplitude of power to the ejection heating element ascompared to dispensing the aerosol precursor composition. In someembodiments heating the aerosol precursor composition with the atomizermay include heating the aerosol precursor composition with avaporization heating element.

In an additional aspect, a method for aerosolization in an aerosoldelivery device is provided. The method may include directing an airflowfrom a control body comprising a power source through a cartridgeincluding a reservoir. Further, the method may include dispensing anaerosol precursor composition from the reservoir via a bubble jet head.Additionally, the method may include heating the aerosol precursorcomposition dispensed from the reservoir by the bubble jet head with anatomizer.

In some embodiments dispensing the aerosol precursor composition andheating the aerosol precursor composition may include independentlyapplying power from the power source to the bubble jet head and theatomizer. Dispensing the aerosol precursor composition and heating theaerosol precursor composition may include directing power to theatomizer after applying power to the bubble jet head. The method mayadditionally include preheating the aerosol precursor composition withthe bubble jet head prior to dispensing the aerosol precursorcomposition. Further, the method may include detecting a temperature ofthe aerosol precursor composition. Preheating the aerosol precursorcomposition may include preheating the aerosol precursor composition toa desired temperature. Preheating the aerosol precursor composition mayinclude applying a relatively smaller pulse width or pulse amplitude ofpower to the bubble jet head as compared to dispensing the aerosolprecursor composition.

These and other features, aspects, and advantages of the disclosure willbe apparent from a reading of the following detailed descriptiontogether with the accompanying drawings, which are briefly describedbelow. The invention includes any combination of two, three, four, ormore of the above-noted embodiments as well as combinations of any two,three, four, or more features or elements set forth in this disclosure,regardless of whether such features or elements are expressly combinedin a specific embodiment description herein. This disclosure is intendedto be read holistically such that any separable features or elements ofthe disclosed invention, in any of its various aspects and embodiments,should be viewed as intended to be combinable unless the context clearlydictates otherwise.

BRIEF DESCRIPTION OF THE FIGURES

Having thus described the disclosure in the foregoing general terms,reference will now be made to the accompanying drawings, which are notnecessarily drawn to scale, and wherein:

FIG. 1 illustrates an exploded view of a control body according to anexample embodiment of the present disclosure;

FIG. 2 illustrates an exploded view of an aerosol delivery deviceincluding a combined dispenser and atomizer assembly comprising astandard bubble jet head according to an example embodiment of thepresent disclosure;

FIG. 3 illustrates a modified sectional view through the aerosoldelivery device of FIG. 2 showing airflow therethrough according to anexample embodiment of the present disclosure;

FIG. 4 illustrates a modified sectional view through the combineddispenser and atomizer assembly of the aerosol delivery device of FIG. 2according to an example embodiment of the present disclosure;

FIG. 5 illustrates a perspective modified sectional view through theaerosol delivery device of FIG. 2 at the combined dispenser and atomizerassembly and a reservoir according to an example embodiment of thepresent disclosure;

FIG. 6 illustrates a modified sectional view through the aerosoldelivery device of FIG. 2 showing production of vapor according to anexample embodiment of the present disclosure;

FIG. 7 illustrates a sectional view through an additional embodiment ofan aerosol delivery device including an integral combined dispenser andatomizer assembly according to an example embodiment of the presentdisclosure;

FIG. 8 illustrates a sectional view through the aerosol delivery deviceof FIG. 7 showing airflow therethrough according to an exampleembodiment of the present disclosure;

FIG. 9 illustrates a sectional view through the combined dispenser andatomizer assembly of the aerosol delivery device of FIG. 7 according toan example embodiment of the present disclosure;

FIG. 10 illustrates an enlarged sectional view through the combineddispenser and atomizer assembly of the aerosol delivery device of FIG. 7according to an example embodiment of the present disclosure;

FIG. 11 illustrates a partial sectional view through the aerosoldelivery device of FIG. 7 showing production of vapor according to anexample embodiment of the present disclosure;

FIG. 12 illustrates a sectional view through an aerosol delivery deviceincluding a combined dispenser and atomizer assembly including aflexible circuit according to an additional example embodiment of thepresent disclosure;

FIG. 13 illustrates an enlarged, partial, sectional view through theaerosol delivery device of FIG. 12 at the combined dispenser andatomizer assembly according to an example embodiment of the presentdisclosure;

FIG. 14 illustrates a modified sectional view through the aerosoldelivery device of FIG. 12 showing airflow therethrough according to anexample embodiment of the present disclosure;

FIG. 15 illustrates a partial sectional view through an aerosol deliverydevice that is substantially similar to the aerosol delivery device ofFIG. 12, except the aerosol delivery device includes an integralcombined dispenser and atomizer assembly according to an additionalexample embodiment of the present disclosure;

FIG. 16 illustrates a sectional view through an aerosol delivery deviceincluding a combined dispenser and atomizer assembly positioned betweena reservoir and a mouthpiece according to an additional exampleembodiment of the present disclosure;

FIG. 17 illustrates an enlarged, partial, sectional view through theaerosol delivery device of FIG. 16 showing airflow therethroughaccording to an example embodiment of the present disclosure;

FIG. 18 illustrates a sectional view through an aerosol delivery deviceincluding a combined dispenser and atomizer assembly coupled to alateral side of a reservoir according to an additional exampleembodiment of the present disclosure;

FIG. 19 illustrates an enlarged, partial, modified sectional viewthrough the aerosol delivery device of FIG. 18 showing airflowtherethrough according to an example embodiment of the presentdisclosure;

FIG. 20 illustrates a partial, schematic view of an aerosol deliverydevice wherein respective ejection and heating surfaces of a bubble jethead and an atomizer are oriented at a non-zero angle with respect to alongitudinal axis of the aerosol delivery device according to anadditional example embodiment of the present disclosure;

FIG. 21 illustrates a sectional view through an aerosol delivery deviceincluding a combined dispenser and atomizer assembly wherein airflowoccurs centrally therethrough according to an additional exampleembodiment of the present disclosure;

FIG. 22 illustrates an enlarged sectional view through the aerosoldelivery device of FIG. 21 showing airflow therethrough according to anexample embodiment of the present disclosure;

FIG. 23 schematically illustrates an enlarged exploded view of thecombined dispenser and atomizer assembly of the aerosol delivery deviceof FIG. 21 according to an example embodiment of the present disclosure;

FIG. 24 illustrates a perspective view of a substantially conicalatomizer defining an inner heating surface according to an additionalexample embodiment of the present disclosure;

FIG. 25 illustrates a perspective view of a substantially conicalatomizer defining an outer heating surface according to an additionalexample embodiment of the present disclosure;

FIG. 26 illustrates an exploded view of a combined dispenser andatomizer assembly including a reinforcement member according to anadditional example embodiment of the present disclosure;

FIG. 27 illustrates an opposing view of the combined dispenser andatomizer assembly of FIG. 26 wherein the reinforcement member is in anassembled configuration according to an example embodiment of thepresent disclosure;

FIG. 28A illustrates an enlarged sectional view through an atomizer ofthe combined dispenser and atomizer assembly of FIG. 26 wherein theatomizer defines a crenellated heating surface according to anadditional example embodiment of the present disclosure;

FIG. 28B illustrates an enlarged sectional view through an atomizer ofthe combined dispenser and atomizer assembly of FIG. 26 wherein theatomizer defines a partially porous heating surface according to anadditional example embodiment of the present disclosure;

FIG. 28C illustrates an enlarged sectional view through an atomizer ofthe combined dispenser and atomizer assembly of FIG. 26 wherein theatomizer defines a fully porous heating surface according to anadditional example embodiment of the present disclosure;

FIG. 29 illustrates a sectional view through an aerosol delivery devicewherein a combined dispenser and atomizer assembly is positioned in acontrol body according to an additional example embodiment of thepresent disclosure;

FIG. 30 illustrates a sectional view through an aerosol delivery devicecomprising a control body, a dispenser and atomizer cartridge, and areservoir cartridge according to an additional example embodiment of thepresent disclosure; and

FIG. 31 schematically illustrates a method for aerosolization in anaerosol delivery device according to an additional example embodiment ofthe present disclosure.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The present disclosure will now be described more fully hereinafter withreference to exemplary embodiments thereof. These exemplary embodimentsare described so that this disclosure will be thorough and complete, andwill fully convey the scope of the disclosure to those skilled in theart. Indeed, the disclosure may be embodied in many different forms andshould not be construed as limited to the embodiments set forth herein;rather, these embodiments are provided so that this disclosure willsatisfy applicable legal requirements. As used in the specification, andin the appended claims, the singular forms “a”, “an”, “the”, includeplural variations unless the context clearly dictates otherwise.

As described hereinafter, embodiments of the present disclosure relateto aerosol delivery systems, devices, and components therefor. Aerosoldelivery systems according to the present disclosure use electricalenergy to heat a material (preferably without combusting the material toany significant degree) to form an inhalable substance; and componentsof such systems have the form of articles that are most preferablysufficiently compact to be considered hand-held devices. That is, use ofcomponents of preferred aerosol delivery systems does not result in theproduction of smoke in the sense that aerosol results principally fromby-products of combustion or pyrolysis of tobacco, but rather, use ofthose preferred systems results in the production of vapors resultingfrom volatilization or vaporization of certain components incorporatedtherein. In preferred embodiments, components of aerosol deliverysystems may be characterized as electronic cigarettes, and thoseelectronic cigarettes most preferably incorporate tobacco and/orcomponents derived from tobacco, and hence deliver tobacco derivedcomponents in aerosol form.

Aerosol generating pieces of certain preferred aerosol delivery systemsmay provide many of the sensations (e.g., inhalation and exhalationrituals, types of tastes or flavors, organoleptic effects, physicalfeel, use rituals, visual cues such as those provided by visibleaerosol, and the like) of smoking a cigarette, cigar, or pipe that isemployed by lighting and burning tobacco (and hence inhaling tobaccosmoke), without any substantial degree of combustion of any componentthereof. For example, the user of an aerosol generating piece of thepresent disclosure can hold and use that piece much like a smokeremploys a traditional type of smoking article, draw on one end of thatpiece for inhalation of aerosol produced by that piece, take or drawpuffs at selected intervals of time, and the like.

Aerosol delivery systems of the present disclosure also can becharacterized as being suitable vapor-producing articles or medicamentdelivery articles. Thus, such articles or devices can be adapted so asto provide one or more substances (e.g., flavors and/or pharmaceuticalactive ingredients) in an inhalable form or state. For example,inhalable substances can be substantially in the form of a vapor (i.e.,a substance that is in the gas phase at a temperature lower than itscritical point). Alternatively, inhalable substances can be in the formof an aerosol (i.e., a suspension of fine solid particles or liquiddroplets in a gas).

Aerosol delivery systems of the present disclosure most preferablycomprise some combination of a power source (i.e., an electrical powersource), at least one control component (e.g., means for actuating,controlling, regulating and/or ceasing power supplied for heatgeneration, such as by controlling electrical cul ent flow from anelectrical power release unit to other components of the aerosolgenerating piece), a heater or heat generation component (e.g., anelectrical resistance heating element and related components commonlyreferred to as providing an “atomizer”), and an aerosol precursor (e.g.,a composition that commonly is a liquid capable of yielding an aerosolupon application of sufficient heat, such as ingredients commonlyreferred to as “smoke juice,” “e-liquid” and “e-juice”), and a mouthendregion or tip for allowing draw upon the aerosol delivery device foraerosol inhalation (e.g., a defined air flow path through the aerosolgeneration piece such that aerosol generated can be withdrawn therefromupon draw by a user).

More specific formats, configurations and arrangements of componentswithin the aerosol delivery systems of the present disclosure will beevident in light of the further disclosure provided hereinafter.Additionally, the selection and arrangement of various aerosol deliverysystem components can be appreciated upon consideration of thecommercially available electronic aerosol delivery devices, such asthose representative products referenced in background art section ofthe present disclosure.

Alignment of the components within the aerosol delivery device can vary.In specific embodiments, the aerosol precursor composition can belocated near an end of the article (e.g., within a cartridge, which incertain circumstances can be replaceable and disposable), which may beconfigured to be positioned proximal to the mouth of a user so as tomaximize aerosol delivery to the user. Other configurations, however,are not excluded. Generally, the components can be configured relativeto one another so that heat from the heating element can volatilize theaerosol precursor composition (as well as one or more flavorants,medicaments, or the like that may likewise be provided for delivery to auser) and form an aerosol for delivery to the user. When the heatingelement heats the aerosol precursor composition, an aerosol is formed,released, or generated in a physical form suitable for inhalation by aconsumer. It should be noted that the foregoing terms are meant to beinterchangeable such that reference to release, releasing, releases, orreleased includes form or generate, forming or generating, forms orgenerates, and formed or generated. Specifically, an inhalable substanceis released in the form of a vapor or aerosol or mixture thereof.

An aerosol delivery device incorporates a battery or other electricalpower source to provide current flow sufficient to provide variousfunctionalities to the article, such as powering of a heater, poweringof control systems, powering of indicators, and the like. The powersource can take on various embodiments. Preferably, the power source isable to deliver sufficient power to rapidly heat the heating element toprovide for aerosol formation and power the article through use for thedesired duration of time. The power source preferably is sized to fitconveniently within the aerosol delivery device so that the aerosoldelivery device can be easily handled; and additionally, a preferredpower source is of a sufficiently light weight to not detract from adesirable smoking experience.

An aerosol delivery device can include a cartridge and a control bodythat can be permanently or detachably aligned in a functioningrelationship. Various embodiments of engagement between the cartridgeand the control body may be employed such as a threaded engagement, apress-fit engagement, an interference fit, a magnetic engagement, or thelike. The aerosol delivery device may be substantially rod-like,substantially tubular shaped, or substantially cylindrically shaped insome embodiments when the cartridge and the control body are in anassembled configuration.

In specific embodiments, one or both of the cartridge and the controlbody may be referred to as being disposable or as being reusable. Forexample, the control body may have a replaceable battery or arechargeable battery and thus may be combined with any type ofrecharging technology, including connection to a typical alternatingcurrent electrical outlet, connection to a car charger (i.e., cigarettelighter receptacle), and connection to a computer, such as through auniversal serial bus (USB) cable. Further, in some embodiments thecartridge may comprise a single-use cartridge, as disclosed in U.S. Pat.Pub. No. 2014/0060555 to Chang et al., which is incorporated herein byreference in its entirety.

In some embodiments a cartridge may include a base that may compriseanti-rotation features that substantially prevent relative rotationbetween the cartridge and the control body as disclosed in U.S. Pat.App. Pub. No. 2014/0261495 to Novak et al., which is incorporated hereinby reference in its entirety.

An aerosol delivery device may include a component configured to hold anaerosol precursor composition. The aerosol precursor composition, alsoreferred to as a vapor precursor composition, may comprise a variety ofcomponents including, by way of example, a polyhydric alcohol (e.g.,glycerin, propylene glycol, or a mixture thereof), nicotine, tobacco,tobacco extract, and/or flavorants. Various components that may beincluded in the aerosol precursor composition are described in U.S. Pat.No. 7,726,320 to Robinson et al., which is incorporated herein byreference in its entirety. Additional representative types of aerosolprecursor compositions are set forth in U.S. Pat. No. 4,793,365 toSensabaugh, Jr. et al.; U.S. Pat. No. 5,101,839 to Jakob et al.; U.S.Pat. Pub. No. 2013/0008457 to Zheng et al.; PCT WO 98/57556 to Biggs etal.; and Chemical and Biological Studies on New Cigarette Prototypesthat Heat Instead of Burn Tobacco, R. J. Reynolds Tobacco CompanyMonograph (1988); the disclosures of which are incorporated herein byreference in their entireties.

A variety of heater components may be used in the present aerosoldelivery device. In various embodiments, one or more microheaters orlike solid state heaters may be used. Embodiments of microheaters thatmay be utilized are further described herein. Further microheaters andatomizers incorporating microheaters suitable for use in the presentlydisclosed devices are described in U.S. Pat. Pub. No. 2014/0060554 toCollett et al., which is incorporated herein by reference in itsentirety. In some embodiments a heating element may be formed by windinga wire about a liquid transport element as described in U.S. Pat. App.Pub. No. 2014/0157583 to Ward et al., which is incorporated herein byreference in its entirety. Further, in some embodiments the wire maydefine a variable coil spacing, as described in U.S. Pat. App. Pub. No.2014/0270730 to DePiano et al., which is incorporated herein byreference in its entirety. Various embodiments of materials configuredto produce heat when electrical current is applied therethrough may beemployed to form a resistive heating element. Example materials fromwhich the wire coil may be formed include Kanthal (FeCrAl), Nichrome,Molybdenum disilicide (MoSi₂), molybdenum silicide (MoSi), Molybdenumdisilicide doped with Aluminum (Mo(Si,Al)₂), graphite and graphite-basedmaterials; and ceramic (e.g., a positive or negative temperaturecoefficient ceramic). In further embodiments a stamped heating elementmay be employed in the atomizer, as described in U.S. Pat. App. Pub. No.2014/0270729 to DePiano et al., which is incorporated herein byreference in its entirety. Further to the above, additionalrepresentative heating elements and materials for use therein aredescribed in U.S. Pat. No. 5,060,671 to Counts et al.; U.S. Pat. No.5,093,894 to Deevi et al.; U.S. Pat. No. 5,224,498 to Deevi et al.; U.S.Pat. No. 5,228,460 to Sprinkel Jr., et al.; U.S. Pat. No. 5,322,075 toDeevi et al.; U.S. Pat. No. 5,353,813 to Deevi et al.; U.S. Pat. No.5,468,936 to Deevi et al.; U.S. Pat. No. 5,498,850 to Das; U.S. Pat. No.5,659,656 to Das; U.S. Pat. No. 5,498,855 to Deevi et al.; U.S. Pat. No.5,530,225 to Hajaligol; U.S. Pat. No. 5,665,262 to Hajaligol; U.S. Pat.No. 5,573,692 to Das et al.; and U.S. Pat. No. 5,591,368 to Fleischhaueret al., the disclosures of which are incorporated herein by reference intheir entireties. Further, chemical heating may be employed in otherembodiments. Various additional examples of heaters and materialsemployed to form heaters are described in U.S. Pat. Pub. No.2014/0060554 to Collett et al., which is incorporated herein byreference, as noted above.

In some embodiments the aerosol delivery devices of the presentdisclosure may include a control body and a cartridge. When the controlbody is coupled to the cartridge, an electronic control component in thecartridge may form an electrical connection with the control body. Thecontrol body may thus employ the electronic control component todetermine whether the cartridge is genuine and/or perform otherfunctions. Further, various examples of electronic control componentsand functions performed thereby are described in U.S. Pat. App. Pub. No.2014/0096781 to Sears et al., which is incorporated herein by referencein its entirety.

During use, a user may draw on a mouthpiece of the cartridge of theaerosol delivery device. This may pull air through an opening in thecontrol body or in the cartridge. For example, in one embodiment anopening may be defined between the coupler and the outer body of thecontrol body, as described in U.S. Pat. App. Pub. No. 2014/0261408 toDePiano et al., which is incorporated herein by reference in itsentirety. However, the flow of air may be received through other partsof the aerosol delivery device in other embodiments.

A sensor in the aerosol delivery device (e.g., a puff or flow sensor inthe control body) may sense the puff. When the puff is sensed, thecontrol body may direct current to the heater through a circuit.Accordingly, the heater may vaporize the aerosol precursor composition,and the mouthpiece may allow passage of air and entrained vapor (i.e.,the components of the aerosol precursor composition in an inhalableform) from the cartridge to a consumer drawing thereon.

Various other details with respect to the components that may beincluded in the cartridge, are provided, for example, in U.S. Pat. App.Pub. No. 2014/0261495 to Novak et al., which is incorporated herein byreference in its entirety. In this regard, FIG. 7 thereof illustrates anenlarged exploded view of a base and a control component terminal; FIG.8 thereof illustrates an enlarged perspective view of the base and thecontrol component terminal in an assembled configuration; FIG. 9 thereofillustrates an enlarged perspective view of the base, the controlcomponent terminal, an electronic control component, and heaterterminals of an atomizer in an assembled configuration; FIG. 10 thereofillustrates an enlarged perspective view of the base, the atomizer, andthe control component in an assembled configuration; FIG. 11 thereofillustrates an opposing perspective view of the assembly of FIG. 10thereof; FIG. 12 thereof illustrates an enlarged perspective view of thebase, the atomizer, the flow tube, and the reservoir substrate in anassembled configuration; FIG. 13 thereof illustrates a perspective viewof the base and an outer body in an assembled configuration; FIG. 14thereof illustrates a perspective view of a cartridge in an assembledconfiguration; FIG. 15 thereof illustrates a first partial perspectiveview of the cartridge of FIG. 14 thereof and a coupler for a controlbody; FIG. 16 thereof illustrates an opposing second partial perspectiveview of the cartridge of FIG. 14 thereof and the coupler of FIG. 11thereof; FIG. 17 thereof illustrates a perspective view of a cartridgeincluding a base with an anti-rotation mechanism; FIG. 18 thereofillustrates a perspective view of a control body including a couplerwith an anti-rotation mechanism; FIG. 19 thereof illustrates alignmentof the cartridge of FIG. 17 with the control body of FIG. 18; FIG. 20thereof illustrates an aerosol delivery device comprising the cartridgeof FIG. 17 thereof and the control body of FIG. 18 thereof with amodified view through the aerosol delivery device illustrating theengagement of the anti-rotation mechanism of the cartridge with theanti-rotation mechanism of the connector body; FIG. 21 thereofillustrates a perspective view of a base with an anti-rotationmechanism; FIG. 22 thereof illustrates a perspective view of a couplerwith an anti-rotation mechanism; and FIG. 23 thereof illustrates asectional view through the base of FIG. 21 thereof and the coupler ofFIG. 22 thereof in an engaged configuration.

Various components of an aerosol delivery device according to thepresent disclosure can be chosen from components described in the artand commercially available. Reference is made for example to thereservoir and heater system for controllable delivery of multipleaerosolizable materials in an electronic smoking article disclosed inU.S. Pat. Pub. No. 2014/0000638 to Sebastian et al., which isincorporated herein by reference in its entirety.

In the present disclosure, FIG. 1 illustrates an exploded view of acontrol body 300 of an aerosol delivery device according to an exampleembodiment. As illustrated, the control body 300 may comprise a coupler302, an outer body 304, a sealing member 306, an adhesive member 308(e.g., KAPTON® tape), a flow sensor 310 (e.g., a puff sensor or pressureswitch), a control component 312, a spacer 314, an electrical powersource 316 (e.g., a battery, which may be rechargeable), a circuit boardwith an indicator 318 (e.g., a light emitting diode (LED)), a connectorcircuit 320, and an end cap 322. Examples of electrical power sourcesare described in U.S. Pat. App. Pub. No. 2010/0028766 by Peckerar etal., the disclosure of which is incorporated herein by reference in itsentirety. An exemplary mechanism that can provide puff-actuationcapability includes a Model 163PC01D36 silicon sensor, manufactured bythe MicroSwitch division of Honeywell, Inc., Freeport, Ill. Furtherexamples of demand-operated electrical switches that may be employed ina heating circuit according to the present disclosure are described inU.S. Pat. No. 4,735,217 to Gerth et al., which is incorporated herein byreference in its entirety. Further description of current regulatingcircuits and other control components, including microcontrollers thatcan be useful in the present aerosol delivery device, are provided inU.S. Pat. Nos. 4,922,901, 4,947,874, and 4,947,875, all to Brooks etal., U.S. Pat. No. 5,372,148 to McCafferty et al., U.S. Pat. No.6,040,560 to Fleischhauer et al., and U.S. Pat. No. 7,040,314 to Nguyenet al., all of which are incorporated herein by reference in theirentireties. Reference also is made to the control schemes described inU.S. App. Pub. No. 2014/0270727 to Ampolini et al., which isincorporated herein by reference in its entirety.

In one embodiment the indicator 318 may comprise one or more lightemitting diodes. The indicator 318 can be in communication with thecontrol component 312 through the connector circuit 320 and illuminate,for example, during a user drawing on a cartridge coupled to the coupler302, as detected by the flow sensor 310. The end cap 322 may be adaptedto make visible the illumination provided thereunder by the indicator318. Accordingly, the indicator 318 may illuminate during use of theaerosol delivery device to simulate the lit end of a smoking article.However, in other embodiments the indicator 318 can be provided invarying numbers and can take on different shapes and can even be anopening in the outer body (such as for release of sound when suchindicators are present).

Still further components can be utilized in the aerosol delivery devicesof the present disclosure. For example, U.S. Pat. No. 5,154,192 toSprinkel et al. discloses indicators for smoking articles; U.S. Pat. No.5,261,424 to Sprinkel, Jr. discloses piezoelectric sensors that can beassociated with the mouth-end of a device to detect user lip activityassociated with taking a draw and then trigger heating; U.S. Pat. No.5,372,148 to McCafferty et al. discloses a puff sensor for controllingenergy flow into a heating load array in response to pressure dropthrough a mouthpiece; U.S. Pat. No. 5,967,148 to Harris et al. disclosesreceptacles in a smoking device that include an identifier that detectsa non-uniformity in infrared transmissivity of an inserted component anda controller that executes a detection routine as the component isinserted into the receptacle; U.S. Pat. No. 6,040,560 to Fleischhauer etal. describes a defined executable power cycle with multipledifferential phases; U.S. Pat. No. 5,934,289 to Watkins et al. disclosesphotonic-optronic components; U.S. Pat. No. 5,954,979 to Counts et al.discloses means for altering draw resistance through a smoking device;U.S. Pat. No. 6,803,545 to Blake et al. discloses specific batteryconfigurations for use in smoking devices; U.S. Pat. No. 7,293,565 toGriffen et al. discloses various charging systems for use with smokingdevices; U.S. Pat. No. 8,402,976 to Fernando et al. discloses computerinterfacing means for smoking devices to facilitate charging and allowcomputer control of the device; U.S. Pat. No. 8,689,804 to Fernando etal. discloses identification systems for smoking devices; and WO2010/003480 by Flick discloses a fluid flow sensing system indicative ofa puff in an aerosol generating system; all of the foregoing disclosuresbeing incorporated herein by reference in their entireties. Furtherexamples of components related to electronic aerosol delivery articlesand disclosing materials or components that may be used in the presentarticle include U.S. Pat. No. 4,735,217 to Gerth et al.; U.S. Pat. No.5,249,586 to Morgan et al.; U.S. Pat. No. 5,666,977 to Higgins et al.;U.S. Pat. No. 6,053,176 to Adams et al.; U.S. Pat. No. 6,164,287 toWhite; U.S. Pat. No. 6,196,218 to Voges; U.S. Pat. No. 6,810,883 toFelter et al.; U.S. Pat. No. 6,854,461 to Nichols; U.S. Pat. No.7,832,410 to Hon; U.S. Pat. No. 7,513,253 to Kobayashi; U.S. Pat. No.7,896,006 to Hamano; U.S. Pat. No. 6,772,756 to Shayan; U.S. Pat. Nos.8,156,944 and 8,375,957 to Hon; U.S. Pat. No. 8,794,231 to Thorens etal. and U.S. Pat. No. 8,851,083 to Oglesby et al.; U.S. Pat. App. Pub.Nos. 2006/0196518 and 2009/0188490 to Hon; U.S. Pat. App. Pub. Nos.2009/0260641 and 2009/0260642 to Monsees et al.; U.S. Pat. App. Pub. No.2010/0024834 to Oglesby et al.; U.S. Pat. App. Pub. No. 2010/0307518 toWang; U.S. Pat. App. Pub. No. 2014/0261408 to DePiano et al.; WO2010/091593 to Hon; WO 2013/089551 to Foo, each of which is incorporatedherein by reference in its entirety. A variety of the materialsdisclosed by the foregoing documents may be incorporated into thepresent devices in various embodiments, and all of the foregoingdisclosures are incorporated herein by reference in their entireties.

Accordingly, example embodiments of aerosol delivery devices aredescribed above. However, the present disclosure provides various otherembodiments of aerosol delivery devices. As described hereinafter, suchaerosol delivery devices may include differing configurations ofcomponents for storing, delivering, and/or vaporizing an aerosolprecursor composition. Some of the components of the aerosol deliverydevices may be substantially similar to the components described above,and hence details with respect to these components and the functionthereof will not be repeated or only briefly described. However, itshould be understood that the description of components provided aboveis equally applicable to the embodiments of aerosol delivery devicesdescribed hereinafter unless otherwise noted.

In this regard, FIG. 2 illustrates an exploded view of an aerosoldelivery device 1200 according to an additional example embodiment ofthe present disclosure. As illustrated, the aerosol delivery device 1200may include a control body 1202 and a cartridge 1204. The control body1202 may include an end cap 1206, a circuit board with an indicator 1208(e.g., a light emitting diode (LED)), a connector circuit 1209, anelectrical power source 1210 (e.g., a battery, which may berechargeable), a flow sensor 1212, a coupler 1214, and an outer body1216 (which may include one or more inlet apertures 1233). The cartridge1204 may include a base 1218, a combined dispenser and atomizer assembly1220, a reservoir 1222, a lid 1224, a mouthpiece 1226, and an outer body1228.

FIG. 3 illustrates a modified sectional view through the aerosoldelivery device 1200 of FIG. 2. As illustrated therein, the base 1218 ofthe cartridge 1204 may be configured to engage the coupler 1214 of thecontrol body 1202 to form a mechanical and electrical connectiontherebetween. The connection between the base 1218 of the cartridge 1204and the coupler 1214 of the control body 1202 may be releasable suchthat, for example, the cartridge may be replaced when an aerosolprecursor composition 1246 (see, FIG. 6) received therein is expended.Although FIG. 2 illustrates wiring 1230 as being coupled to the base1218, the wiring may actually be coupled to the coupler 1214 so as toallow for releasable connection between the cartridge 1204 and thecontrol body 1202 in some embodiments.

FIG. 3 further illustrates a flow path of air through the aerosoldelivery device 1200 when a user draws on the mouthpiece 1226. Asillustrated, an airflow or flow of ambient air 1232 may enter theaerosol delivery device 1200 through the one or more inlet apertures1233 and travel proximate or past the flow sensor 1212. The air 1232 maythen travel through at least one coupler aperture 1261 in the coupler1214 and at least one base aperture 1263 in the base 1218, around thecombined dispenser and atomizer assembly 1220 and the reservoir 1222(e.g., via one or more aerosol delivery apertures 1265 defined in theouter body 1228 or a space between the reservoir and the outer body),and out the mouthpiece 1226.

The inlet apertures 1233 may be defined in the outer body 1216 of thecontrol body 1202 such that the flow sensor 1212, which may also bepositioned in the control body, may detect flow of the air 1232. Thecontrol body 1202 may be reusable, whereas the cartridge 1204 may bedisposable. In this regard, whereas certain components within thecartridge 1204 may degrade or be depleted, the flow sensor 1212 andother components within the control body may maintain full functionalitydespite repeated use. Accordingly, positioning the flow sensor 1212 inthe control body 1202 and providing a corresponding flow path of the air1232 through the control body, or otherwise providing for fluidcommunication of the air traveling through the aerosol delivery device1200 with the flow sensor, may decrease the cost of the cartridge 1204by decreasing the number and type of components received therein. Inthis regard, although airflow is generally described as occurringthrough the control body in this and other embodiments disclosed herein,in additional embodiments a pressure tap may be employed to allow a flowsensor in a control body to detect a flow of air through a cartridgesubstantially without any airflow through the control body as described,for example, in U.S. patent application Ser. No. 14/193,961, filed Feb.28, 2014, to Worm et al., which is incorporated herein by reference inits entirety.

The lid 1224 and the combined dispenser and atomizer assembly 1220 maybe coupled to opposing ends of the reservoir 1222. Accordingly, the lid1224 and the combined dispenser and atomizer assembly 1220 may enclosethe reservoir 1222 and retain the aerosol precursor composition 1246(see, FIG. 6) therein. However, when the flow sensor 1212 detects thepuff, the combined dispenser and atomizer assembly 1220 may be actuatedsuch that the aerosol precursor composition 1246 (see, FIG. 6) iscontrollably dispensed from the reservoir 1222.

In this regard, FIG. 4 illustrates a partial sectional view through thecombined dispenser and atomizer assembly. As illustrated, in oneembodiment the combined dispenser and atomizer assembly 1220 may includea bubble jet head 1234 and an atomizer 1238 fixedly coupled thereto. Asdiscussed in detail below, the bubble jet head 1234 may be configured todispense the aerosol precursor composition 1246 from the reservoir 1222(see, e.g., FIG. 6). Further, the atomizer 1238 may be configured toheat the aerosol precursor composition 1246 to produce an aerosol orvapor 1248 (see, FIG. 6).

The bubble jet head 1234 may include one or more precursor inlets 1245,one or more precursor channels 1235, one or more first or ejectionheating elements 1240, one or more precursor nozzles 1242, and a wafer,substrate, or housing 1241 respectively associated therewith. In someembodiments the housing 1241 may comprise silicon, ceramic, graphite, orother lower thermally-conductive and/or insulating materials. Theprecursor inlets 1245, the precursor channels 1235, and/or precursornozzles 1242 may be defined by apertures in the housing 1241 in someembodiments. Alternatively, the precursor inlets, the precursorchannels, and/or the precursor outlets may comprise separate elementscoupled to the housing. Further, the ejection heating elements 1240 maybe positioned within one or more first or ejection chambers 1237, whichmay be defined by the housing 1241 of the bubble jet head 1234. In someembodiments the bubble jet head 1234 may comprise a standard inkjetprinter head (e.g., a standard bubble jet print head sold by ImTech ofCorvallis, Oreg. or a 45 style jet head sold by Hewlett Packard of PaloAlto, Calif.).

The atomizer 1238 may be positioned relative to the bubble jet head 1234so as to receive the aerosol precursor composition 1246 dispensed fromthe reservoir 1222 (see, FIG. 6). In some embodiments the atomizer 1238may be fixedly coupled to the bubble jet head 1234 such that thecombined dispenser and atomizer assembly 1220 may be inserted into theouter body 1228 of the cartridge 1204 (see, e.g., FIG. 3) as a unit,rather than separately inserted into the outer body. By way of example,the combined dispenser and atomizer assembly 1220 may be engaged withthe reservoir 1222 and the combined assembly may be inserted into theouter body 1228 (see, e.g., FIG. 3). Further, fixedly coupling thebubble jet head 1234 to the atomizer 1238 may allow for preciseplacement of these two components relative to one another such that thedispensed aerosol precursor composition 1246 (see, FIG. 6) is receivedat a proper location on the atomizer for atomization.

As illustrated in FIG. 4, in one embodiment the bubble jet head 1234 maybe fixedly coupled to the atomizer 1238 via one or more spacers 1236. Inparticular, the atomizer 1238 may include a wafer, substrate, or housing1243 that is coupled to the housing 1241 of the bubble jet head 1234 viathe spacers 1236. In some embodiments the housing 1243 may comprisesilicon, ceramic, graphite, or other nonconductive and/or insulatingmaterials. The spacers 1236 may be configured to provide a gap betweenthe bubble jet head 1234 and the atomizer 1238. In some embodiments thegap may be from about 1 mm to about 10 mm, and more preferably fromabout 1 mm to about 3 mm in order to reduce splattering of the aerosolprecursor composition. However, gaps defining differing dimensions maybe employed in other embodiments. In this regard, the gap between thebubble jet head 1234 and the atomizer 1238 may be selected or adjustedto provide accurate delivery of the aerosol precursor composition to theheating surface of the atomizer based on a droplet dispersion patternassociated with ejection of the aerosol precursor composition from thebubble jet head (e.g., to prevent pooling of the aerosol precursorcomposition on one or more portions of the atomizer, to provide a thin,even film of the aerosol precursor composition across the heatingsurface of the atomizer, and/or to target a specific region of theatomizer). The atomizer 1238 may further include one or more second orvaporization heating elements 1244. For example, a respective one of thevaporization heating elements 1244 may be associated with each ejectionheating element 1240 and each nozzle 1242.

The bubble jet head 1234 may be coupled to the reservoir 1222 orotherwise positioned in fluid communication therewith. For example, asillustrated in FIG. 5, in some embodiments the bubble jet head 1234 maybe coupled to a distal end 1222A of the reservoir 1222 so as to block anopening 1222′ to the reservoir and retain the aerosol precursorcomposition 1246 (see, FIG. 6) therein as described above. Thus, theprecursor inlets 1245 in the bubble jet head 1234 may be in fluidcommunication with the reservoir 1222 and thereby the precursor channels1235 may direct the aerosol precursor composition 1246 (see, FIG. 6) tothe ejection chambers 1237 in which the ejection heating elements 1240are positioned.

Coupling the bubble jet head 1234 to the distal end 1222A of thereservoir 1222 may be advantageous in that it provides a relativelysimple mechanism for attachment and fluid coupling. In this regard, thereservoir 1222 may define a hollow, substantially cylindricalconfiguration, and the distal end 1222A may define a substantiallyplanar configuration. Thereby, the bubble jet head 1234 may be coupled(e.g., glued, adhered, or welded) to the distal end 1222A of thereservoir 1222 to enclose the reservoir and provide fluid communicationbetween the reservoir and the bubble jet head.

Accordingly, the bubble jet head 1234 may receive the aerosol precursorcomposition 1246 (see, FIG. 6) from the reservoir 1222. In someembodiments, as illustrated in FIG. 5, the reservoir 1222 may include areservoir substrate 1239 configured to direct the aerosol precursorcomposition 1246 (see, FIG. 6) to the bubble jet head 1234. In thisregard, the reservoir substrate 1239 may comprise any materialconfigured to wick or otherwise transport the aerosol precursorcomposition 1246 (see, FIG. 6) to the bubble jet head 1234, such ascellulose acetate, polyethylene terephthalate (PET), or any polymericmaterial, whether woven or nonwoven and whether fibrous or nonfibrous.Further, in other embodiments the reservoir substrate 1239 may compriseone or more nonpolymeric materials that may be manufactured as an opencell foam or the like (e.g., ceramic foam, carbon foam, sintered glass),such that the material(s) define a porous media that provides wickingchannels. Accordingly, by employing the reservoir substrate 1239, theaerosol precursor composition 1246 (see, FIG. 6) may be directed to thebubble jet head 1234 regardless of the orientation of the aerosoldelivery device 1200 (see, e.g., FIG. 2), such that the aerosol deliverydevice does not have to be oriented in a particular manner during usage.In some embodiments the reservoir substrate may occupy only a portion ofthe longitudinal length of the reservoir. For example, the reservoirsubstrate may only be positioned proximate the distal end of thereservoir to which the bubble jet head is attached. This configurationmay provide substantially the same benefits noted above, becausemovement of the aerosol delivery device may cause the aerosol precursorcomposition to contact the reservoir substrate, while reducing thevolume within the reservoir occupied by the reservoir substrate so as toallow for a greater fluid capacity therein.

The aerosol precursor composition 1246 (see, FIG. 6) may initially beprevented from traveling through the remainder of the combined dispenserand atomizer assembly 1220 by the precursor nozzles 1242. In thisregard, the precursor nozzles 1242 may be appropriately sized to resistflow therethrough due to, for example, surface tension. Alternatively oradditionally, a negative pressure in the reservoir (e.g., as created bya spring and a piston within the reservoir or as a result of applying anegative pressure to the reservoir prior to sealing it shut, may resistpassive leakage of the aerosol precursor composition out of thereservoir and through the bubble jet head.

However, when a puff is detected by the flow sensor 1212, the bubble jethead 1234 may direct the aerosol precursor composition 1246 (see, FIG.6) in the reservoir 1222 toward the atomizer 1238. In particular,current from the power source 1210 (see, e.g., FIG. 2) may be directedto the ejection heating elements 1240 to heat the aerosol precursorcomposition 1246 (see, FIG. 6) received through the precursor inlets1245 and the precursor channels 1235 such that bubbles of vapor form,which eject droplets of the aerosol precursor composition through theprecursor nozzles 1242 toward the atomizer 1238, as described andillustrated in greater detail below with respect to alternativeembodiments of the present disclosure.

Current from the power source 1210 (see, e.g., FIG. 2) may be applied tothe vaporization heating elements 1244 prior to, simultaneously with, orafter applying current to the ejection heating elements 1240. However,delaying application of the current to the vaporization heating elements1244 until after the ejection heating elements 1240 receive current mayassist in preventing wasted energy. In this regard, some of the heatproduced by the vaporization heating elements 1244 prior to the aerosolprecursor composition 1246 (see, FIG. 6) coming in contact therewith maybe undesirably transferred to surrounding portions of the aerosoldelivery device 1200 or air within the aerosol delivery device, ratherthan applied to the aerosol precursor composition as desired.

In one embodiment a plurality of walls defined by the housing 1241 ofthe bubble jet head 1234, the spacers 1236, and/or the housing 1243 ofthe atomizer 1238 may cooperatively define a second or vaporizationchamber 1247 (see, e.g., FIG. 4) in which the vaporization heatingelements 1244 are positioned and to which the aerosol precursorcomposition 1246 (see, FIG. 6) is delivered. Thus, issues with respectto the aerosol precursor composition 1246 (see, FIG. 6) being directedinto the air 1232 and to a user without being vaporized may be avoided.In this regard, the aerosol precursor composition 1246 may be directedinto contact with the vaporization heating elements 1244 at thevaporization chamber 1247 to ensure vaporization thereof, prior to beingdirected into the flow of air 1232 through the aerosol delivery device1200. As illustrated in FIG. 6, the flow of air 1232 may extendgenerally around the combined dispenser and atomizer assembly 1220,rather than flow between the bubble jet head 1234 and the atomizer 1238such that the flow of air does not direct the aerosol precursorcomposition away from the atomizer prior to atomization. Note that ifthe aerosol precursor composition were to be directed into the airwithout being vaporized, the aerosol precursor composition may separatefrom the air and accumulate in the aerosol delivery device at a locationoutside of the reservoir. This could result in undesirable fluid leakagefrom the aerosol delivery device. Alternatively or additionally, theliquid aerosol precursor composition could reach the user's mouth, whichmay cause an undesirable taste or sensation.

Thereby, the droplets of the aerosol precursor composition 1246 ejectedfrom the nozzles 1242 may be vaporized by the vaporization heatingelements 1244 of the atomizer 1238 to produce an aerosol or vapor 1248(see, FIG. 6). As illustrated in FIG. 6, the vapor 1248 produced by thevaporization heating elements 1244 may then exit the combined dispenserand atomizer assembly 1220 and intermix and travel with the air 1232 tothe mouthpiece 1226. Accordingly, the bubble jet head 1234 may beemployed to precisely dispense the aerosol precursor composition 1246(see, FIG. 6) to the atomizer 1238, which may provide advantages interms of ensuring that there is a consistent amount of aerosol deliveredwith each draw on the aerosol delivery device 1200 as compared toembodiments of aerosol delivery devices that rely on passive aerosolprecursor composition delivery mechanisms such as wicks.

The electrical power directed to the bubble jet head 1234 and theatomizer 1238 from the power source 1210 may be controlled in one ormore manners. For example, the power directed to the bubble jet head1234 may be independently controlled relative to the atomizer 1238 inone or more manners. Further, pulse width and/or pulse amplitudemodulation may be employed to provide an appropriate amount of currentto the bubble jet head 1234 and the atomizer 1238. Relatively largerpulse widths and/or amplitudes may be employed to produce a relativelylarger amount of heat. In this regard, the ejection heating elements1240 may have a relatively lower thermal mass and may be configured toheat the aerosol precursor composition 1246 to a relatively lesserdegree than the vaporization heating elements 1244 in order to eject anddispense the aerosol precursor composition, rather than fully vaporizethe aerosol precursor composition, which occurs at the atomizer 1238. Inthis regard, while ejection of the aerosol precursor composition mayinvolve vaporization, only a small portion of the aerosol precursorcomposition is vaporized and the vaporization occurs in thesubstantially enclosed ejection chamber 1237 such that one or moredroplets of the aerosol precursor composition are ejected therefrom. Incontrast, the vaporization heating elements may be configured tovaporize an entirety of the aerosol precursor composition directedthereto. Thus, in order to heat the ejection heating elements 1240 to arelatively lesser degree than the vaporization heating elements 1244,relatively smaller pulse widths and/or amplitudes of power may bedirected to the ejection heating elements as compared to the pulsewidths and/or amplitudes of power directed to the vaporization heatingelements. Further, the application of power to the vaporization heatingelements 1244 may be delayed in relation to application of power to theejection heating elements 1240, such that energy is not wasted at thevaporization heating elements prior to ejection of the aerosol precursorcomposition.

As noted above, in one embodiment the bubble jet head may comprise asubstantially conventional bubble jet head, such as an ink jet heademployed in a printer. However, the ink jet head may be modified for usein the aerosol delivery devices of the present disclosure. For example,the number of precursor nozzles and precursor inlets leading thereto maybe adjusted, the diameter and/or shape of the precursor inlets and/orthe precursor nozzles may be adjusted, the size of the ejection heatingelements in the bubble jet head may be adjusted, the heat outputted bythe ejection heating elements may be adjusted, the pulse width of powerapplied to the ejection heating elements in the bubble jet head may beadjusted, and/or various other characteristics may be adjusted. Thesechanges may accommodate the differences in viscosity of the aerosolprecursor composition versus ink as well as the goal of directing theaerosol precursor composition at an atomizer to vaporize the aerosolprecursor composition, as opposed to printing ink on a substrate such aspaper.

The present disclosure provides various additional embodiments ofaerosol delivery devices including bubble jet heads configured todispense an aerosol precursor composition to an atomizer. For brevitypurposes, description with respect to certain features and components ofthe aerosol delivery devices that are described above will not berepeated below in detail. However, it should be understood that thedescription provided above is applicable to the embodiments of aerosoldelivery devices described below, except where otherwise indicated.

FIG. 7 illustrates a sectional view through an aerosol delivery device1300 according to an additional example embodiment of the presentdisclosure. As illustrated, the aerosol delivery device 1300 may includea control body 1302 and a cartridge 1304. The control body 1302 mayinclude an end cap 1306, a flow sensor 1308, an electrical power source1310 (e.g., a battery, which may be rechargeable), a coupler 1312defining at least one coupler aperture 1361, and an outer body 1314. Thecontrol body may additionally include a circuit board with an indicator(e.g., a light emitting diode (LED)) and a connector circuit asdescribed elsewhere herein. The cartridge 1304 may include a base 1316defining at least one base aperture 1363, a combined dispenser andatomizer assembly 1318, a reservoir 1320, a lid 1322 that encloses thereservoir, a mouthpiece 1324, and an outer body 1326 defining one ormore aerosol delivery apertures 1365. The base 1316 of the cartridge1304 may be configured to engage the coupler 1312 of the control body1302 to form a mechanical and electrical connection therebetween, whichmay be releasable to allow for replacement of the cartridge.

FIG. 8 illustrates a sectional view through the aerosol delivery device1300 showing a flow path of air through the aerosol delivery device whena user draws on the mouthpiece 1324. As illustrated, an airflow or flowof ambient air 1328 may enter the aerosol delivery device 1300 throughone or more inlet apertures 1331 and travel past or proximate the flowsensor 1308 and around the electrical power source 1310. Although theambient air 1328 is illustrated as flowing around the electrical powersource 1310, in other embodiments the air may not flow past theelectrical power source and/or the flow sensor may be positioned at analternative location. Further, the inlet apertures 1331 may bepositioned at various alternate locations and defined in othercomponents, such as in the outer body 1314 of the control body 1302between the electrical power source 1310 and the coupler 1312. The air1328 may flow from the control body 1302 through the aperture 1361 inthe coupler 1312 and into and through the base aperture 1363 in the base1316, around the combined dispenser and atomizer assembly 1318 and thereservoir 1320 (e.g., via the aerosol delivery apertures 1365 defined inthe outer body 1326 or between the reservoir and the outer body), andout the mouthpiece 1324.

When the flow sensor 1308 detects the puff, the combined dispenser andatomizer assembly 1318 may be activated. In this regard, as illustratedin the partial sectional view of FIG. 9, the combined dispenser andatomizer assembly 1318 may receive an aerosol precursor composition 1330from the reservoir 1320 and produce an aerosol or vapor 1332. Moreparticularly, as illustrated in the enlarged partial sectional view ofFIG. 10, the combined dispenser and atomizer assembly 1318 may include awafer, substrate, or housing 1333 defining at least one precursor inlet1334 through which the aerosol precursor composition 1330 is received.The aerosol precursor composition 1330 may then travel through one ormore precursor channels 1335 to one or more precursor nozzles 1336. Insome embodiments the precursor inlet 1334, the precursor channels 1335,and/or the precursor nozzles 1336 may be defined by the housing 1333.Alternatively, the precursor inlets, the precursor channels, and/or theprecursor outlets may comprise separate components coupled to thehousing. The aerosol precursor composition 1330 may initially beprevented from traveling through the remainder of the combined dispenserand atomizer assembly 1318 by the precursor nozzles 1336 leadingthereto. In this regard, the precursor nozzles 1336 may be appropriatelysized to resist flow therethrough due to, for example, surface tension.Alternatively or additionally, the aerosol precursor composition may beexposed to a negative pressure within the reservoir as discussed aboveto reduce the likelihood of fluid leakage through the combined dispenserand atomizer assembly.

However, when the flow sensor 1308 (see, e.g., FIG. 8) detects the puffon the aerosol delivery device 1300, current may be directed from thepower source 1310 (see, e.g., FIG. 8) to one or more first or ejectionheating elements 1338 positioned within a first or ejection chamber 1339defined by the housing 1333. Thereby, the ejection heating elements 1338may heat the aerosol precursor composition 1330 such that the aerosolprecursor composition 1330 boils and bubbles of vapor 1340 form. Eachbubble of vapor 1340 expands extremely rapidly, creating a pressurepulse that then causes a droplet 1342 of the aerosol precursorcomposition 1330 to eject through a respective one of the precursornozzles 1336. After the application of power to the ejection heatingelement 1338 ends, the bubble of vapor 1340 collapses as the aerosolprecursor composition 1330 and the bubble of vapor 1340 cools. Surfacetension and surface energy associated with the aerosol precursorcomposition 1330 at the precursor nozzle 1336 and capillary forces dueto interaction of aerosol precursor composition with the microfluidchannel defined by the precursor inlet 1334, the precursor channels1335, and the precursor nozzles may cause more of the aerosol precursorcomposition to be directed from the reservoir toward the ejectionheating element 1338, such that the aerosol precursor compositionreplenishes the ejection chamber 1337 and such that the ejection cyclemay be repeated. Thus, use of a separate valve may not be required todispense the aerosol precursor composition 1330. Accordingly, thecombined bubble jet head and dispenser 1318 may comprise a bubble jethead 1350 including the ejection heating elements 1338, the precursorinlets 1334, the precursor channels 1335, and the precursor nozzles1336.

As further illustrated in FIG. 10, the droplets 1342 of the aerosolprecursor composition 1330 may be ejected through the precursor nozzles1336 toward one or more second or vaporization heating elements 1344. Inthis regard, each ejection heating element 1338, precursor nozzle 1336,and vaporization heating element 1344 of a respective portion of thecombined dispenser and atomizer assembly 1318 may be axially alignedsuch that aerosol precursor composition 1330 is ejected onto thevaporization heating elements. The vaporization heating elements 1344may be positioned in a second or vaporization chamber 1346 defined bythe housing 1333 and to which droplets 1342 of the aerosol precursorcomposition 1330 are delivered. A respective one of the vaporizationheating elements 1344 may be associated with each ejection heatingelement 1338 and each of the precursor nozzles 1336. Thereby, thedroplets 1342 of the aerosol precursor composition 1330 ejected from theprecursor nozzles 1336 may be vaporized by the vaporization heatingelements 1344 to produce the vapor 1332 (see, e.g., FIG. 9).

In this regard, the ejection heating elements 1338 may have a relativelylower thermal mass and may be configured to heat the aerosol precursorcomposition 1330 to a relatively lesser degree as compared to thevaporization heating elements 1344. The vapor 1332 (see, e.g., FIG. 9)produced by the vaporization heating elements 1344 may then exit thecombined dispenser and atomizer assembly 1318 through one or moreaerosol outlets 1348, which may be defined by the housing 1333 at thesecond chamber 1346. In order to cause the vapor 1332 to exit throughthe aerosol outlets 1348, rather than travel backwards through theprecursor nozzles 1336, the aerosol outlets may define a larger areathan an area of the precursor nozzles. Further, by providing the aerosoloutlets 1348 with a relatively larger area and/or providing the secondchamber 1346 with a relatively large volume, issues with respect to therapid expansion of the aerosol precursor composition 1330 into the vapor1332 (see, e.g., FIG. 9) causing damage to the combined dispenser andatomizer assembly 1318 may be avoided.

As illustrated in FIG. 11, the vapor 1332 may intermix and travel withthe air 1328 toward the mouthpiece 1324 (see, e.g., FIG. 8). Forexample, the vapor 1332 and the air 1328 may travel through the aerosoldelivery apertures 1365 defined in the outer body 1326 of the cartridge1304. As described above, the aerosol precursor composition may beejected into, and vaporized within, the vaporization chambers 1346.Thereby, issues with respect to the aerosol precursor composition beingdirected into the air 1328 (see, e.g., FIG. 8) without first beingatomized may be avoided.

Accordingly, the combined dispenser and atomizer assembly 1318 of FIGS.7-11 may be an integral unit (e.g., provided as a silicon chip)including both the bubble jet head 1350 (e.g., comprising the ejectionheating elements 1338, the precursor inlets 1334, the precursor channels1335, and the precursor nozzles 1336) and an atomizer 1352 (e.g.,comprising the aerosol outlets 1348 and the vaporization heatingelements 1344) fixedly coupled to one another via the housing 1333,which is configured for receipt within the outer body 1326 of thecartridge 1304 (see, e.g., FIG. 8). In contrast, the combined dispenserand atomizer assembly 1220 illustrated in FIGS. 2-6 may include astandard bubble jet head 1234 (e.g., a bubble jet head from an inkjetprinter) which may be fixedly coupled to an atomizer 1238 (e.g., via thespacers 1236) and modified to act as a dispenser for dispensing anaerosol precursor composition to the atomizer.

FIG. 12 illustrates a sectional view through an aerosol delivery device1400 according to an additional example embodiment of the presentdisclosure. As illustrated, the aerosol delivery device 1400 may includea control body 1402 and a cartridge 1404, which are illustrated in adecoupled configuration. The control body 1402 may include an end cap1406, a circuit board with an indicator 1408 (e.g., a light emittingdiode (LED)), a connector circuit 1409, an electrical power source 1410(e.g., a battery, which may be rechargeable), a flow sensor 1411 (e.g.,a puff sensor or pressure switch), a coupler 1412, wiring 1413, and anouter body 1414. The cartridge 1404 may include a base 1416, a combineddispenser and atomizer assembly 1418, a reservoir 1420, a lid 1422 thatencloses the reservoir, a mouthpiece 1424, and an outer body 1426. Thebase 1416 of the cartridge 1404 may be configured to engage the coupler1412 of the control body 1402 to form a mechanical and electricalconnection therebetween, which may be releasable to allow forreplacement of the cartridge.

FIG. 13 illustrates an enlarged partial sectional view of the aerosoldelivery device 1400 wherein the control body 1402 and the cartridge1404 are coupled to one another. As illustrated, the combined dispenserand atomizer assembly 1418 may comprise a bubble jet head 1450 and anatomizer 1452. The bubble jet head 1450 and the atomizer 1452 maycomprise any of the components and features of the bubble jet heads andatomizers described elsewhere herein.

As further illustrated in FIG. 13, the bubble jet head 1450 and theatomizer may be coupled via a flexible circuit 1453. In particular, theflexible circuit 1453 may be electrically coupled to the base 1416 suchthat the dispenser and atomizer assembly 1418 is electrically connectedto the cartridge 1402 through the base and the coupler 1412. Theflexible circuit 1453 may additionally electrically couple the bubblejet head 1450 to the atomizer 1452 such that power may be directed tothe bubble jet head and the atomizer in the manners described elsewhereherein.

Further, in some embodiments the flexible circuit may mechanicallycouple the bubble jet head 1450 to the atomizer 1452 such that thebubble jet head and the atomizer are fixedly coupled to one another. Inthis regard, the flexible circuit 1453 may comprise a high temperaturepolyamide substrate or other flexible, nonconductive material with acircuit printed, etched, or otherwise formed thereon. Further, in someembodiments the combined dispenser and atomizer assembly 1418 may becoupled to the reservoir 1420 and then this assembly may be insertedinto the outer body 1426 of the cartridge 1404. In this regard, themechanical coupling between the bubble jet head 1450 and the atomizer1452 via the flexible circuit 1453 may allow for insertion in thismanner. Further, the flexible circuit 1453 may be configured to flexsuch that, for example, the combined dispenser and atomizer assembly1418 may be pressed against the base 1416 to define a desired gap orseparation between the bubble jet head 1450 and the atomizer 1452. Inthis regard, for example, the flexible circuit 1453 may initiallyposition the bubble jet head 1450 and the atomizer 1452 at a relativelylarge separation and the flexible circuit may flex during assembly forexample, as a result of contact with the base 1416 to define the desiredseparation.

As further illustrated in FIG. 13, in some embodiments the outer body1414 of the control body 1402 may define one or more inlet apertures1431, the coupler 1412 may define at least one coupler aperture 1427,the base 1416 may define at least one base aperture 1429, and the outerbody 1426 of the cartridge 1404 may define at least one aerosol deliveryaperture 1465, which may allow flow of air through the aerosol deliverydevice 1400. In this regard, FIG. 14 illustrates a sectional viewthrough the aerosol delivery device 1400 showing a flow path of airthrough the aerosol delivery device when a user draws on the mouthpiece1424. As illustrated, an airflow or flow of ambient air 1428 may enterthe aerosol delivery device 1400 through the inlet apertures 1431 whichmay be defined in the outer body 1414 of the control body 1402 andtravel past or proximate the flow sensor 1411. The air 1428 may flowfrom the control body 1402 through the coupler 1412 at the coupleraperture 1427 (see, FIG. 13) and through the base aperture 1429 definedin the base 1416 of the cartridge 1404, through and/or around thecombined dispenser and atomizer assembly 1418, around the reservoir 1420(e.g., through the aerosol delivery aperture 1465 defined in the outerbody 1426 or between the reservoir and the outer body, as illustrated inFIG. 15), and out the mouthpiece 1424. Note that although the aerosoldelivery aperture 1465 is illustrated as defining a nonlinear flow path,in other embodiments the aerosol delivery aperture may define a linearflow path (e.g., extending parallel to the longitudinal length of thecartridge) in order to simplify manufacturing of the cartridge andprovide a flow path with a smaller pressure drop.

In particular, the air 1428 may travel through the base 1416 via the atleast one base aperture 1429 (see, FIG. 13). As illustrated in FIG. 13,the base aperture 1429 may be positioned proximate a radially outer edgeof the base 1412. Thereby, as illustrated in FIG. 14, the air 1428 mayenter the cartridge proximate an inner surface of the outer body 1426.The air 1428 may flow around and partially through the combineddispenser and atomizer assembly 1418 between the bubble jet head 1450and the atomizer 1452 (see, FIG. 13).

When the flow sensor 1411 detects the puff, the combined dispenser andatomizer assembly 1418 may be activated such that the bubble jet head1450 ejects the aerosol precursor composition from the reservoir 1420toward the atomizer 1452 (see, FIG. 13). Although the above-describedconfiguration of the flow of at least part of the air 1428 through thecombined dispenser and atomizer assembly 1418 may result in the aerosolprecursor composition being ejected into the flow of air 1428 prior toatomization, usage of the base aperture 1429 may regulate flow of theair through the combined dispenser and atomizer assembly such thatsubstantially all of the aerosol precursor composition may come intocontact with the atomizer 1452 (see, FIG. 13) and become atomized,rather than become entrained with the air in liquid form and thereafterpotentially separate therefrom. Further, some of the air 1428 may flowaround, rather than through, the combined dispenser and atomizerassembly 1418, such that the flow of the air may be distributed across arelatively large area and thereby the flow of the air through thecombined dispenser and atomizer assembly may define a relatively lowvelocity which may not affect dispensing of the aerosol precursorcomposition onto the atomizer 1452 (see, FIG. 13) to a great extent.Additionally, the flexible circuit 1453 and/or housings of the bubblejet head 1450 and the atomizer 1452 may define a vaporization chamberthat further resists directing the aerosol precursor composition intothe flow of air 1428 without being atomized. In some embodiments theatomizer may be shifted downstream of the bubble jet head to account formovement of the aerosol precursor composition caused by the flow of air.Following atomization, the air and vapor may travel around the reservoir1422 and out the mouthpiece 1424 to the user. Note that the embodimentsof the aerosol delivery device including a flex circuit may beconfigured to avoid issues with respect to liquid aerosol precursorcomposition becoming entrained with air without being vaporized. In thisregard, for example, the bubble jet head and the atomizer may be spacedrelatively close to one another and the atomizer may be heated to such atemperature that the aerosol precursor composition may be atomized evenif it does not contact the atomizer.

As noted above, the flexible circuit 1453 may be employed to establish amechanical and electrical connection between a bubble jet head 1450 andan atomizer 1452 of a combined dispenser and atomizer assembly 1418.However, the flexible circuit 1453 may also be configured toelectrically connect the combined dispenser and atomizer assembly 1418and the power source 1410 in the cartridge through the coupler 1412 andthe base 1416. In this regard, various other embodiments of combineddispensers and atomizer assemblies may be electrically connected to oneor more other components of an aerosol delivery device via a flexiblecircuit.

For example, FIG. 15 illustrates a partial sectional view of anembodiment of an aerosol delivery device 1400′ that is substantiallysimilar to the aerosol delivery device 1400 of FIGS. 12-14. However, asillustrated, the aerosol delivery device 1400′ of FIG. 15 may include acombined dispenser and atomizer assembly 1418′ comprising a sharedwafer, substrate, or housing 1433′, in which both a bubble jet head andan atomizer are housed. In this regard, for example, the combineddispenser and atomizer assembly 1418′ of FIG. 15 may be substantiallysimilar to the combined dispenser and atomizer assembly 1318 of FIG. 9.In this embodiment, the flexible circuit 1453 may be employed to providean electrical connection to the combined dispenser and atomizer assemblyregardless of whether or not the bubble jet head and the atomizer arepositioned within separate housings or a shared housing. Note also thatusage of the combined dispenser and atomizer assembly 1418′ including abubble jet head and the atomizer within the shared housing 1433′,through which air does not flow, may avoid any issues with respect tothe liquid precursor composition being carried by the flow of airwithout atomization.

FIG. 16 illustrates a sectional view through an aerosol delivery device1500 according to an additional example embodiment of the presentdisclosure. As illustrated, the aerosol delivery device 1500 may includea control body 1502 and a cartridge 1504, which are illustrated in adecoupled configuration. In this regard, a base 1516 of the cartridge1504 may be configured to engage a coupler 1512 of the control body 1502to form a mechanical and electrical connection therebetween, which maybe releasable to allow for replacement of the cartridge.

The control body 1502 may include an end cap 1506, a circuit board withan indicator 1508 (e.g., a light emitting diode (LED)), a connectorcircuit 1509, an electrical power source 1510 (e.g., a battery, whichmay be rechargeable), a flow sensor 1511 (e.g., a puff sensor orpressure switch), the coupler 1512, wiring 1513, and an outer body 1514.The cartridge 1504 may include the base 1516, a combined dispenser andatomizer assembly 1518, a reservoir 1520, a mouthpiece 1524, aninsulator 1555, and an outer body 1526. In the illustrated embodimentthe coupler 1516 defines a lid 1522 that encloses the reservoir 1520. Inthis regard, by sealing shut an end of the reservoir 1520 with thecoupler 1516, assembly of the cartridge 1504 may be simplified. However,in other embodiments the lid may comprise a component that is separatefrom the coupler.

FIG. 17 illustrates an enlarged partial sectional view of the aerosoldelivery device 1500 wherein the control body 1502 and the cartridge1504 are coupled to one another. As illustrated, the combined dispenserand atomizer assembly 1518 may comprise a bubble jet head 1550 and anatomizer 1552, which may be fixedly coupled to one another (e.g., by oneor more spacers). The bubble jet head 1550 and the atomizer 1552 maycomprise any of the components and features of the bubble jet heads andatomizers described elsewhere herein.

FIG. 17 further illustrates a flow path of air through the aerosoldelivery device 1500 when a user draws on the mouthpiece 1524. Asillustrated, an airflow or flow of ambient air 1528 may enter theaerosol delivery device 1500 through one or more inlet apertures 1531which may be defined in the outer body 1514 of the control body 1502 andtravel past or proximate the flow sensor 1511. The air 1528 may flowfrom the control body 1502 through at least one coupler aperture 1561defined in the coupler 1512 and through one or more base apertures 1529defined in the base 1516 of the cartridge 1504, around the reservoir1520 (e.g., through one or more air delivery channels 1565 defined inthe outer body 1526 or between the reservoir and the outer body), aroundand partially through the combined dispenser and atomizer assembly 1518,and out the mouthpiece 1524.

As a result of this configuration, some or all of the air 1528 may flowlaterally across the cartridge 1504 through the combined dispenser andatomizer assembly 1518 between a bubble jet head 1550 and an atomizer1552. When the flow sensor 1511 detects the puff, the combined dispenserand atomizer assembly 1518 may be activated such that the bubble jethead 1550 ejects the aerosol precursor composition from the reservoir1520 toward the atomizer 1552.

Although the above-described configuration of the flow of at least partof the air 1528 through the combined dispenser and atomizer assembly1518 may result in the aerosol precursor composition being ejected intothe flow of air 1528 prior to atomization, usage of the one or more baseapertures 1529 may regulate flow of the air through the combineddispenser and atomizer assembly such that substantially all of theaerosol precursor composition may come into contact with the atomizer1552 (see, FIG. 13) and become atomized, rather than become entrainedwith the air in liquid form and thereafter potentially separatetherefrom. Further, some of the air 1528 may flow around, rather thanthrough, the combined dispenser and atomizer assembly 1518, such thatthe flow of the air may be distributed across a relatively large areaand thereby the flow of the air through the combined dispenser andatomizer assembly may define a relatively low velocity which may notaffect dispensing of the aerosol precursor composition onto the atomizer1552 (see, FIG. 13) to a great extent. Further, as described above, oneor more spacers and/or housings of the bubble jet head 1550 and theatomizer 1552 may define a vaporization chamber that further resistsdirecting the aerosol precursor composition into the flow of air 1528without being atomized and/or the atomizer may be positioned downstreamof the bubble jet head to account for movement of the aerosol precursorcomposition caused by the flow of air. Following atomization, the airand vapor may travel around the reservoir 1522 and out the mouthpiece1524 to the user.

Note that in the aerosol delivery devices 1200, 1300, 1400 of FIGS. 2-15the reservoir is positioned between the mouthpiece and the combineddispenser and atomizer assembly, which may comprise a bubble jet headand an atomizer. This configuration may be desirable in that itpositions the atomizer distally from the mouthpiece such that the user'smouth does not come into contact with a heated surface. In contrast, thecombined dispenser and atomizer assembly 1518 of the aerosol deliverydevice 1500 of FIGS. 16 and 17 is positioned between the reservoir 1520and the mouthpiece 1524. This configuration may be preferable in thatthe aerosol produced by the atomizer may only have to travel arelatively short distance to the mouthpiece 1524 such that the potentialfor the aerosol precursor composition to condense out of the air 1528after vaporization is reduced. However, in order to keep the mouthpiece1524 and/or the outer body 1526 cool to the touch at areas which a usermay contact with his or her lips, the aerosol delivery device 1500 mayfurther comprise an insulator 1555, as illustrated in FIG. 16. Theinsulator 1555 may comprise any embodiment of insulating materials suchas plastic, fiberglass, or phenolic materials. Further, the insulator1555 may be positioned proximate, or define, one or both of the outerbody 1526 and the mouthpiece 1524 or a portion thereof.

FIG. 18 illustrates a sectional view through an aerosol delivery device1600 according to an additional example embodiment of the presentdisclosure. As illustrated, the aerosol delivery device 1600 may includea control body 1602 and a cartridge 1604, which are illustrated in acoupled configuration. In this regard, a base 1616 of the cartridge 1604may be configured to engage a coupler 1612 of the control body 1602 toform a mechanical and electrical connection therebetween, which may bereleasable to allow for replacement of the cartridge.

The control body 1602 may include an end cap 1606, a circuit board withan indicator 1608 (e.g., a light emitting diode (LED)), a connectorcircuit 1609, an electrical power source 1610 (e.g., a battery, whichmay be rechargeable), a flow sensor 1611 (e.g., a puff sensor orpressure switch), the coupler 1612, wiring 1613, and an outer body 1614.The cartridge 1604 may include the base 1616, a combined dispenser andatomizer assembly 1618, a reservoir 1620, a mouthpiece 1624, and anouter body 1626. In the illustrated embodiment the coupler 1616 definesa lid 1622 that encloses the reservoir 1620. In this regard, by sealingshut an end of the reservoir 1620 with the coupler 1616, assembly of thecartridge 1604 may be simplified. However, in other embodiments the lidmay comprise a component that is separate from the coupler.

FIG. 19 illustrates an enlarged partial sectional view of the aerosoldelivery device 1600 wherein the control body 1602 and the cartridge1604 are coupled to one another. As illustrated, the combined dispenserand atomizer assembly 1618 may comprise a bubble jet head 1650 and anatomizer 1652, which may be fixedly coupled to one another (e.g., by oneor more spacers 1636). The bubble jet head 1650 and the atomizer 1652may comprise any of the components and features of the bubble jet headsand atomizers described elsewhere herein.

As further illustrated in FIG. 18, outer body 1614 of the control body1602 may define one or more inlet apertures 1631, the coupler 1612 maydefine at least one coupler aperture 1661, the base 1616, and may defineat least one base aperture 1629, which may allow flow of air through theaerosol delivery device 1600. In this regard, FIG. 19 furtherillustrates a flow path of air through the aerosol delivery device 1600when a user draws on the mouthpiece 1624. As illustrated, an airflow orflow of ambient air 1628 may enter the aerosol delivery device 1600through the inlet apertures 1631, which may be defined in the outer body1614 of the control body 1602, and travel past or proximate the flowsensor 1611. The air 1628 may flow from the control body 1602 throughthe coupler aperture 1661 defined in the coupler 1612 and through thebase 1616 of the cartridge 1604 via the base aperture 1629, between thereservoir 1620 and the outer body 1626, around and partially through thecombined dispenser and atomizer assembly 1618, and out the mouthpiece1624. When the flow sensor 1611 detects the puff, the combined dispenserand atomizer assembly 1618 may be activated such that the bubble jethead 1650 ejects the aerosol precursor composition from the reservoir1620 toward the atomizer 1652.

Although the above-described configuration of the flow of at least partof the air 1628 through the combined dispenser and atomizer assembly1618 may result in the aerosol precursor composition being ejected intothe flow of air 1628 prior to atomization, usage of the at least onebase aperture 1629 may regulate flow of the air through the combineddispenser and atomizer assembly such that substantially all of theaerosol precursor composition may come into contact with the atomizer1652 and become atomized, rather than become entrained with the air inliquid form and thereafter potentially separate therefrom. Further, someof the air 1628 may flow around, rather than through, the combineddispenser and atomizer assembly 1618, such that the flow of the air maybe distributed across a relatively large area and thereby the flow ofthe air through the combined dispenser and atomizer assembly may definea relatively low velocity which may not affect dispensing of the aerosolprecursor composition onto the atomizer 1652 to a great extent. Further,as described above, the spacers 1636 and/or housings of the bubble jethead 1650 and the atomizer 1652 may define a vaporization chamber thatfurther resists directing the aerosol precursor composition into theflow of air 1628 without being atomized, and/or the atomizer may bepositioned downstream from the bubble jet head to account for movementof the aerosol precursor composition caused by the flow of air.Following atomization, the air and vapor may travel around the reservoir1620 and out the mouthpiece 1624 to the user.

As illustrated in FIGS. 18 and 19, the combined dispenser and atomizerassembly may be positioned proximate the mouthpiece 1624, which mayprovide benefits in terms of avoiding condensation of the vaporizedaerosol precursor condensation within the aerosol delivery device asdescribed above. An insulator may be employed proximate the mouthpiecein order to reduce the amount of heat transferred to a user's lips asfurther described above. As further illustrated in FIG. 19, in someembodiments the combined dispenser and atomizer assembly 1618 may becoupled to a lateral side 1655 of the reservoir 1620. This configurationmay allow for substantially longitudinal flow through the combineddispenser and atomizer assembly 1618 and to the mouthpiece 1624. In thisregard, a heating surface of the atomizer 1652 (e.g., comprising theouter surfaces of vaporization heating elements as described above) andan ejection surface of the bubble jet head 1650 (e.g., comprising theprecursor nozzles) may be oriented substantially parallel to alongitudinal axis of the outer body 1626 of the cartridge 1604 and alongitudinal axis of the aerosol delivery device 1600 as a whole.Thereby, flow of the air 1628 may occur between parallel surfacesdefined by the bubble jet head 1650 and the atomizer 1652 such that theflow of air and aerosol may proceed in a substantially linear manner tothe mouthpiece 1624.

In contrast, the embodiments of aerosol delivery devices 1200, 1300,1400, 1500 described above include embodiments of a combined dispenserand atomizer assembly attached to a distal end of the reservoir in amanner whereby the heating surface of the atomizer and the ejectionsurface of the bubble jet head are oriented substantially perpendicularto the outer body of the cartridge and a longitudinal axis of theaerosol delivery device as a whole. Although attaching the combineddispenser and atomizer assembly to the distal end of the reservoirprovides for simplified construction of the aerosol delivery device,this configuration may result in a non-linear air flow path through theaerosol delivery device. For example, as illustrated in FIG. 14, the airmay make one or more sharp turns entering and/or exiting the combineddispenser and atomizer assembly when the bubble jet head and theatomizer are oriented perpendicularly to a longitudinal axis of theaerosol delivery device. These sharp turns may undesirably increase thepressure drop associated with usage of the aerosol delivery device suchthat a draw thereon may require relatively greater effort. Further,sharp turns in the air flow path at or downstream of the combineddispenser and atomizer assembly may be detrimental in that suchtransitions may cause the aerosol to condense back into liquid form as aresult of impacting surrounding structures within the aerosol deliverydevice (e.g., the outer body of the cartridge). Thus, usage of an airflow path that is generally oriented parallel to a longitudinal axis ofthe cartridge, and which does not include sharp turns may be desirable.In this regard, the aerosol delivery device 1600 illustrated in FIGS. 18and 19 is configured to avoid the above-noted problems. However, itshould also be noted that usage of bubble jet heads and atomizersoriented such that respective ejection and heating surfaces thereof aresubstantially perpendicular to a longitudinal axis of the cartridge, asdescribed in the embodiments of aerosol delivery devices of FIGS. 2-17,may be desirable in that such a configuration may define a relativelyslower airflow therethrough, such that atomization of the aerosolprecursor composition may be improved.

Although the bubble jet head and the atomizer of the aerosol deliverydevice of FIGS. 18 and 19 are illustrated as being configured such thatrespective ejection and heating surfaces thereof are orientedsubstantially parallel to the longitudinal axis of the cartridge and theaerosol delivery device as a whole, certain embodiments of aerosoldelivery devices including bubble jet heads and the atomizers in whichrespective ejection and heating surfaces are oriented at non-zero angleswith respect to a longitudinal axis of the outer body may still providemany of the benefits described above with respect to the aerosoldelivery device 1600 of FIGS. 18 and 19. In this regard, FIG. 20illustrates a partial, schematic view of an aerosol delivery device 1700including a combined dispenser and atomizer assembly 1718 whereinrespective ejection and heating surfaces of a bubble jet head 1750 andan atomizer 1752 thereof are oriented at a non-zero angle with respectto a longitudinal axis 1770 of the aerosol delivery device. However, theangle between these surfaces and the longitudinal axis 1770 arerelatively small (e.g., less than about 45 degrees), such that apressure drop caused by the turns in a flow path of air 1728 beforeexiting a mouthpiece 1724 is reduced as compared to embodiments ofaerosol delivery devices that are otherwise similar but define sharperturns in the flow path. Further, the relatively small angles between theejection and heating surfaces of the bubble jet head 1750 and theatomizer 1752 and the longitudinal axis 1770 may also assist in avoidingissues with respect to condensation of the aerosol followingvaporization and introduction into the flow of the air 1728, because theair and aerosol exiting the combined dispenser and atomizer assembly maysmoothly exit therefrom without making a sharp turn.

FIG. 21 illustrates a sectional view through an aerosol delivery device1800 according to an additional example embodiment of the presentdisclosure. As illustrated, the aerosol delivery device 1800 may includea control body 1802 and a cartridge 1804, which are illustrated in acoupled configuration. In this regard, a base 1816 of the cartridge 1804may be configured to engage a coupler 1812 of the control body 1802 toform a mechanical and electrical connection therebetween, which may bereleasable to allow for replacement of the cartridge.

The control body 1802 may include an end cap 1806, a circuit board withan indicator 1808 (e.g., a light emitting diode (LED)), a connectorcircuit 1809, an electrical power source 1810 (e.g., a battery, whichmay be rechargeable), a flow sensor 1811 (e.g., a puff sensor orpressure switch), the coupler 1812, wiring 1813, and an outer body 1814.The cartridge 1804 may include the base 1816, a combined dispenser andatomizer assembly 1818, a reservoir 1820, a mouthpiece 1824, and anouter body 1826. In the illustrated embodiment the coupler 1816 definesa lid 1822 that encloses the reservoir 1820. In this regard, by sealingshut an end of the reservoir 1820 with the coupler 1816, assembly of thecartridge 1804 may be simplified. However, in other embodiments the lidmay comprise a component that is separate from the coupler.

FIG. 22 illustrates an enlarged partial sectional view of the aerosoldelivery device 1800 wherein the control body 1802 and the cartridge1804 are coupled to one another. As illustrated, the combined dispenserand atomizer assembly 1818 may comprise a bubble jet head 1850 and anatomizer 1852, which may be fixedly coupled to one another (e.g., by oneor more spacers 1836). The bubble jet head 1850 and the atomizer 1852may comprise any of the components and features of the bubble jet headsand atomizers described elsewhere herein.

FIGS. 21 and 22 further illustrate a flow path of air through theaerosol delivery device 1800 when a user draws on the mouthpiece 1824.As illustrated in FIG. 21, an airflow or flow of ambient air 1828 mayenter the aerosol delivery device 1800 through one or more inletapertures 1831 which may be defined in the outer body 1814 of thecontrol body 1802 and travel past or proximate the flow sensor 1811. Asillustrated in FIG. 22, the air 1828 may flow from the control body 1802through a coupler inlet 1861 defined in the coupler 1812 and into thebase 1816 of the cartridge 1804, through the reservoir 1820, through thecombined dispenser and atomizer assembly 1818, and out the mouthpiece1824.

In particular, the air 1828 may travel through the base 1816 via atleast one base aperture 1829. Further, the reservoir 1820 may define achannel 1854 extending therethrough. In this regard, the reservoir 1820may define an elongated annular configuration such that the aerosolprecursor enclosed therein is separated from the channel 1854 (e.g., byan inner wall of the reservoir defining the channel). The channel 1854may direct the flow of air 1828 to the combined dispenser and atomizerassembly 1818. In this regard, the bubble jet head 1850 may include anair flow aperture 1856 and the atomizer 1852 may include an aerosoldelivery aperture 1858 configured to direct the flow of air 1828therethrough. In the illustrated embodiment the base aperture 1829, thechannel 1854 through the reservoir 1820, the air flow aperture 1856through the bubble jet head 1850, and the aerosol delivery aperture 1858through the atomizer 1852 are linearly arranged along a longitudinalaxis extending through the cartridge 1804 such that the flow of air 1828travels along a substantially linear path and thereby issues withrespect to increasing a pressure drop of the aerosol delivery device1800 and causing condensation may be averted. The aerosol deliverydevice 1800 may be further configured to avoid the production ofcondensation as a result of the combined dispenser and atomizer assembly1818 being positioned between the reservoir 1820 and the mouthpiece1824. As discussed above, an insulator may be employed to reduce heattransfer to the mouthpiece and the outer body.

FIG. 23 schematically illustrates an enlarged exploded view of thecartridge 1804 proximate the combined dispenser and atomizer assembly1818. As illustrated, the reservoir 1820, the bubble jet head 1850, andthe atomizer 1852 may be configured to dispense and atomize the aerosolprecursor composition in a radial or an annular manner. In this regard,as schematically illustrated, the precursor inlets, precursor channels,ejection heating elements, and/or precursor nozzles of the bubble jethead 1850 may be positioned at a plurality of radial positions 1860annularly about the air flow aperture 1856 extending through the bubblejet head. Similarly, a vaporization heating element 1862 of the atomizer1852 may extend substantially radially and annularly about the aerosoldelivery aperture 1858 extending through the atomizer. Thisconfiguration may allow for dispensing and atomizing of the aerosolprecursor composition around, rather than in, the direct flow of air1828 through the aerosol delivery device 1800, so as to avoid directingliquid aerosol precursor composition into the flow of air. Thisconfiguration may also facilitate the substantially linear flow of air1828, to combine the benefits of the aerosol delivery devices describedabove.

In the embodiments of aerosol delivery devices described above, theatomizer has generally been described as defining a substantially planarheating surface at which the vaporization heating element(s) arepositioned. In this regard, the bubble jet heads have defined anejection surface on which the precursor nozzles are positioned that isalso generally planar and parallel to the heating surface of theatomizer. Thereby, the bubble jet head has ejected the aerosol precursorcomposition substantially perpendicularly to the heating surface of theatomizer. However, various other configurations of atomizers may beemployed.

For example, FIG. 24 illustrates an atomizer 1900 according to analternate embodiment of the present disclosure. The atomizer 1900 may beemployed in conjunction with any of the combined dispenser and atomizerassemblies discussed elsewhere herein. For example, the atomizer 1900may be employed in place of the atomizer 1852 of the combined dispenserand atomizer assembly 1818 of the aerosol delivery device of FIGS.21-23.

As illustrated, the atomizer 1900 may include an inner heating surface1902 that is non-planar. In particular, the atomizer 1900 and the innerheating surface 1902 of the atomizer may be substantially conical (e.g.,defining a hollow truncated conical configuration, as illustrated). Inthis regard, the atomizer 1900 may be configured to receive a flow ofair and aerosol precursor composition 1904 therethrough, such that theinner heating surface 1902 of the atomizer receives the flow of air andaerosol precursor composition 1904 thereon.

Thereby, the heating surface 1902 may atomize the aerosol precursorcomposition. For example, a plurality of vaporization heating elements1906 may be positioned on the inner heating surface 1902. By way offurther example, in some embodiments the heating elements may behelically arranged on the inner heating surface 1902. This configurationmay advantageously contact a majority of the aerosol precursorcomposition directed through the atomizer 1900. Thereby, a flow of airand aerosol 1908 may exit the atomizer 1900.

FIG. 25 illustrates an alternate embodiment of an atomizer 2000, whichmay be employed in place of the atomizer 1852 of the combined dispenserand atomizer assembly 1818 of the aerosol delivery device of FIGS.21-23. The atomizer 2000 may include an outer heating surface 2002. Asillustrated, the atomizer 2000 as a whole, in addition to the outerheating surface 2002, may define a substantially conical configuration.In this embodiment a flow of air and aerosol precursor composition 2004may be directed toward a narrow end of the atomizer 2000. Thereby, theaerosol precursor composition may be vaporized by one or morevaporization heating elements 2006 positioned at the outer heatingsurface 2002 to produce a flow of air and aerosol 2008. The vaporizationheating elements 2006 may be helically arranged on the outer heatingsurface 2002 in order to advantageously heat and vaporize the aerosolprecursor composition.

Note also that although usage of multiple vaporization heating elements1906, 2006 is generally discussed above, in other embodiments a singlevaporization heating element may be employed. For example, thevaporization heating element may comprise a single, continuous embeddedor printed filament at the heating surface. By way of further example,the single continuous filament may define a helical configuration (e.g.,at the inner heating surface in the atomizer illustrated in FIG. 24 orat the outer heating surface in the atomizer illustrated in FIG. 25), asdescribed above. Usage of a single continuous filament for thevaporization heating element may be preferable in that it may simplifyconstruction of the atomizer.

Thus, in some embodiments a heating surface of an atomizer may define anon-planar configuration. Usage of an atomizer including a non-planarheating surface may allow for various alternate flow configurationsthrough aerosol delivery devices. In particular, the substantiallyconical atomizers of FIGS. 24 and 25 may be respectively configured tofocus or distribute air and aerosol while still providing for asubstantially straight air flow path with a minimal increase in pressuredrop associated with a puff on the aerosol delivery device. In these andother embodiments of combined dispenser and atomizers, the bubble jethead may direct the aerosol precursor composition at a non-perpendicularangle relative to the heating surface of the atomizer. By avoidingdirecting the aerosol precursor composition directly normal to theheating surface of the atomizer, issues with respect to aerosolprecursor composition splattering may be avoided. In this regard,splattered aerosol precursor composition may deflect back toward thebubble jet head, which could cause the bubble jet head to clog. Further,in the embodiment of the atomizer 1900 of FIG. 24, any splatteredaerosol precursor composition may be retained within the atomizer andcontact another portion of the inner heating surface 1902, such that thesplattered aerosol precursor still becomes vaporized due to the innerheating surface of the atomizer defining a chamber. Various otherembodiments of frustoconical atomizers are described in U.S. patentapplication Ser. No. 14/329,334, filed Jul. 11, 2014, to Taluskie etal., which is incorporated herein by reference in its entirety.

FIG. 26 illustrates an exploded view of an alternate embodiment of acombined dispenser and atomizer assembly 2100 which may be included inembodiments of the aerosol delivery devices disclosed herein. Asillustrated, the combined dispenser and atomizer assembly 2100 mayinclude a bubble jet head 2102 and an atomizer 2104. Details withrespect to embodiments of bubble jet heads are described above and willnot be repeated in their entirety. Briefly, however, the bubble jet head2102 may include a wafer, substrate, or housing 2106 which may define atleast one precursor inlet 2108 (see, FIG. 27) configured to receive anaerosol precursor composition from a reservoir and at least oneprecursor nozzle 2110 configured to dispense the aerosol precursorcomposition to the atomizer 2104.

Further, the atomizer 2104 may comprise a wafer, substrate, or housing2112. Additionally, as illustrated, in some embodiments the atomizer2104 may further comprise a reinforcement member 2114. The reinforcementmember 2114 may be configured to support the housing 2112 of theatomizer 2104 to provide structural stability thereto. For example, asillustrated in FIG. 27, the reinforcement member 2114 may be coupled tothe housing 2112 of the atomizer 2104 such that the housing issupported. In particular, the reinforcement member 2114 may be coupledto a back of the housing 2112, wherein at least one vaporization heatingelement 2116 is coupled to the front of the housing, opposite thereto.

In this regard, the reinforcement member may be configured to providestiffness, support, and structure to the atomizer 2014 withoutsubstantially increasing the thermal mass thereof. It may be desirableto provide the atomizer 2104 with a relatively low thermal mass suchthat the atomizer may rapidly heat to a temperature sufficient tovaporize the aerosol precursor composition when current is appliedthereto. Thus, the atomizer 2104 may rapidly heat when a user draws onthe associated aerosol delivery device.

By positioning the reinforcement member 2114 opposite from thevaporization heating element 2116, the reinforcement member may avoiddirect contact with the heating element to reduce heat transfer to thereinforcement member. Further, as illustrated in FIG. 26, thereinforcement member 2114 may define a cutout 2118. The cutout 2118 mayfurther reduce the thermal mass of the atomizer 2104 while stillallowing the reinforcement member 2114 to provide the atomizer withimproved strength. In this regard, the cutout may be centrally locatedsuch that the reinforcement member defines a frame extending around anouter edge of the housing 2112. This configuration results in only arelatively small loss in the moment of inertia of the reinforcementmember 2114 while also positioning the mass thereof away from thevaporization heating element 2116 to further reduce heat transfer to thereinforcement member. Additionally, the reinforcement member 2114 maycomprise plastic, ceramic, glass, or other embodiments of insulating andnon-conductive materials that are configured to avoid heat andelectrical transfer thereto.

As illustrated in FIG. 27, the atomizer 2104 may further comprise one ormore conductive pads 2120. The conductive pads 2120 may be configured tocontact the vaporization heating element 2116 to direct current thereto.However, in order to prevent the conductive pads 2120 from undesirablyproducing heat, the conductive pads may comprise a material and/orconfiguration (e.g., thicker gauge) that defines a lower resistance thana material of the vaporization heating element 2116. For example, theconductive pads 2120 may comprise silver palladium and the vaporizationheating element 2116 may comprise platinum. By way of further example,in some embodiments the conductive pads 2120 may comprise silverpalladium, and the vaporization heating element 2116 may comprise asilver palladium formulation defining a relatively greater resistance.However, as may be understood, various other materials may be employedin other embodiments including, for example, gold, silver, platinum,palladium, tungsten and combinations thereof. The materials defining theconductive pads and the vaporization heating element may be selected todefine a desired resistance and appropriate bonding attributes withrespect to the housing and/or other portions of the atomizer.

In some embodiments the atomizer 2104 may be configured to fixedlyengage the bubble jet head 2102 via posts 2103 (see, FIG. 27). In thisregard, as illustrated in FIG. 26, the housing 2112 and/or thereinforcement member 2114 may define recesses 2122 a, 2122 b configuredto engage the posts 2103. In some embodiments the posts 2103 mayelectrically couple the bubble jet head 2102 to the atomizer 2104. Thus,for example, the conductive pads 2120 may be positioned proximate therecesses 2122 a, 2122 b defined in the atomizer 2104 such that anelectrical connection may be established therebetween.

As noted above, it may be desirable to avoid splattering of an aerosolprecursor composition dispensed onto an atomizer. Thus, embodiments ofthe aerosol delivery devices of the present disclosure may includeadditional or alternative features configured to mitigate splattering ofthe aerosol precursor composition and perform other functions. In thisregard, FIGS. 28A-C illustrate enlarged partial views of embodiments ofthe atomizer 2104 of FIGS. 26 and 27 wherein the heating surface thereofis textured, rather than smooth. Note, however, that such texturing maybe employed on any of the atomizers described herein.

In particular, FIG. 28A illustrates an embodiment of the atomizer 2104Awherein a heating surface 2124A is crenellated. In other words, theheating surface 2124A defines a substantially regular pattern ofprotrusions and recesses. FIG. 28B illustrates an embodiment of theatomizer 2104B wherein a heating surface 2124B is partially porous. Inthis regard, the topography of the heating surface 2124B may besubstantially similar to that of a closed-cell foam. FIG. 28Cillustrates an embodiment of the atomizer 2104C wherein a heatingsurface 2124C is fully porous. In this regard, the topography of theheating surface 2102C may be substantially similar to that of anopen-celled foam or a sintered material.

In some embodiments the heating surface 2124A-C may be defined by, orcoated with a passivation layer positioned at an outer surface thereof(e.g., on top of the housing 2112 and the vaporization heating element2116. In this regard, the passivation layer is configured to preventoxidation, catalytic reactions, and various other chemical reactionsfrom occurring at the atomizer when an aerosol precursor composition2128 is sprayed thereon. For example, the passivation layer may comprisealuminum oxide, glass, or a ceramic material, which may be sputtered orotherwise deposited over the vaporization heating elements 2116 and thehousing 2112.

By employing a textured heating surface, the aerosol precursorcomposition may be less prone to splattering due to the textured heatingsurface capturing deflected aerosol precursor composition such that theaerosol precursor composition is less likely to deflect back to thebubble jet head. Further, usage of a textured heating surface mayincrease an effective area of the heating surface upon which the aerosolprecursor composition is directed. Accordingly, heat may be moreefficiently transferred to the aerosol precursor composition to improvevaporization of the aerosol precursor composition.

In some embodiments the heating surface may include a wicking orabsorptive layer, which may optionally define the textured surface, andwhich may be configured to reduce splatter and heat loss and performother functions as described hereinafter. The absorptive layer, whichmay comprise alumina paper in some embodiments, may be positionedoutside of the passivation layer and may be configured to receive theaerosol precursor composition. Thereby, the aerosol precursorcomposition may saturate the absorptive layer, so that heat is appliedto the aerosol precursor composition absorbed within this layer. In thisembodiment the bubble jet head may replenish the aerosol precursorcomposition within the absorptive layer as it is vaporized. In thisregard, the absorptive layer may be at least partially saturated withthe aerosol precursor composition in advance of receiving a draw on theaerosol delivery device, such that aerosol may be produced more rapidly.

Note that although particular embodiments of atomizers are describedabove, various other embodiments of atomizers may be employed tovaporize the aerosol precursor composition in the embodiments of aerosoldelivery devices provided herein. Such atomizers may include flatheaters, wound wire surfaces, micro heaters (e.g., embodied on a chip)glass plates, lasers, resistive heaters, and any other shape andembodiment of heater. For example, in one embodiment a vaporizationheating element may be respectively associated with each precursornozzle and each ejection heating element of the bubble jet head.However, in other embodiments multiple precursor nozzles and multipleejection heating elements (e.g., all of the precursor nozzles and theejection heating elements of the bubble jet head) may eject the aerosolprecursor composition onto a single vaporization heating element tovaporize the aerosol precursor composition. Further, the materialsemployed in the ejection heating elements and the vaporization heatingelements may vary. For example, the materials described above withrespect to wire coil heating elements may be employed. Various othermaterials which may be employed in the ejection heating elements and thevaporization heating elements as well as the various other heatingelements described herein may include platinum or a platinum-coatedmaterials and resistive inks (e.g., printed on a ceramic material).

In another embodiment the housing for one or both of the bubble jet headand the atomizer may comprise a silicon chip. In this embodiment, one orboth of the vaporization heating elements and the ejection heatingelements may comprise the doped silicon of the silicon chip. In otherwords, part of the silicon chip may define a resistive circuitconfigured to produce heat to eject or vaporization the aerosolprecursor composition.

In embodiments of aerosol delivery devices including a bubble jet head,it may be desirable to reduce the viscosity of the aerosol precursorcomposition to facilitate dispensing droplets of the aerosol precursorcomposition as discussed above. Accordingly, in one embodiment theaerosol precursor composition may be preheated. For example, theejection heating elements may be employed to preheat the aerosolprecursor composition prior to heating the aerosol precursor compositionto an extent such that a bubble of vapor forms and a droplet of theaerosol precursor composition is ejected through a precursor nozzle.Such preheating may involve applying a pulsed current to the ejectionheating elements. In this regard, a relatively smaller pulse width ofpower may be applied to the ejection heating elements of the bubble jethead during preheating the aerosol precursor composition as compared toa pulse width of the power applied to the ejection heating elements ofthe bubble jet head during dispensing of the aerosol precursorcomposition. In another embodiment the aerosol precursor composition maybe diluted (e.g., with water) to decrease the viscosity thereof.Accordingly, use of the bubble jet head with an aerosol precursorcomposition may be facilitated in either or both of these manners. Inone embodiment the viscosity of the aerosol precursor composition mayinitially define a range from about 5 to about 400 centipoise at 20degrees Celsius. However, the viscosity of the aerosol precursorcomposition may be reduced through either or both of dilution (e.g., viawater) or preheating to define a viscosity of less than about 100centipoise at 20 degrees Celsius. In comparison, ink employed in inkjetprinters may generally define a relatively lower viscosity (e.g., fromabout 10 to about 40 centipoise at 20 degrees Celsius).

In the embodiments provided herein, the combined dispenser and atomizerassembly has generally been described as being positioned in acartridge. However, in another embodiment the bubble jet head and/or theatomizer may be positioned in the control body. For example, in oneembodiment the bubble jet head may be positioned in the control body andconfigured to eject the aerosol precursor composition toward an atomizerin the cartridge. In this embodiment the aerosol precursor compositionmay be directed from a reservoir in the cartridge to the bubble jet headin the control body and back to the atomizer in the cartridge. Inanother embodiment the bubble jet head may be positioned in thecartridge and configured to eject the aerosol precursor composition froma reservoir in the cartridge toward an atomizer in the control body.

Further, FIG. 29 illustrates an alternate embodiment of an aerosoldelivery device 2200 wherein a combined dispenser and atomizer assemblyis positioned in the control body. As illustrated, the aerosol deliverydevice 2200 may include a control body 2202 and a cartridge 2204, whichare illustrated in a decoupled configuration. In this regard, a base2216 of the cartridge 2204 may be configured to engage a coupler 2212 ofthe control body 2202 to form a mechanical and electrical connectiontherebetween, which may be releasable to allow for replacement of thecartridge.

The control body 2202 may include an end cap 2206, a circuit board withan indicator 2208 (e.g., a light emitting diode (LED)), a connectorcircuit 2209, an electrical power source 2210 (e.g., a battery, whichmay be rechargeable), a flow sensor 2211 (e.g., a puff sensor orpressure switch), the coupler 2212, wiring 2213, a combined dispenserand atomizer assembly 2218, and an outer body 2214. In some embodimentsthe control body 2202 may further comprise a mounting plate 2219, andthe combined dispenser and atomizer assembly 2218 may be mounted betweenthe mounting plate and the coupler 2212. In the illustrated embodiment abubble jet head 2250 of the combined dispenser and atomizer assembly2218 may be coupled to the coupler 2212, an atomizer 2252 of thecombined dispenser and atomizer assembly may be coupled to the mountingplate 2219, and the bubble jet head may be coupled to the atomizer via aflexible circuit 2253.

The cartridge 2204 may include the base 2216, a reservoir 2220, a lid2222 that encloses the reservoir, a mouthpiece 2224, and an outer body2226. When the cartridge 2204 is coupled to the control body 2202, thereservoir 2220 may be in fluid communication with the bubble jet head2250. In this regard, the reservoir 2220 may define an outlet 2256. Insome embodiments the base 2216 may also define an outlet 2258 that mayalign with the outlet 2256 to the reservoir 2220. One or both of theoutlets 2256, 2258 may be initially sealed to retain an aerosolprecursor composition in the reservoir 2220. In this regard, by way ofexample, a foil or plastic seal may cover the outlets 2256, 2258.However, the seal may be broken (e.g., by piercing the seal) when thebase 2216 of the cartridge 2204 is engaged with the coupler 2212 of thecontrol body 2202. Thereby, by positioning the bubble jet head 2250 inproximity to the coupler 2212, the bubble jet head may receive theaerosol precursor composition transferred from the reservoir 2220through the outlets 2256, 2258 and through an inlet 2260 at the coupler.Thereby, the bubble jet head 2250 may dispense the aerosol precursorcomposition to the atomizer 2252 to produce an aerosol. A flow of airmay enter through one or more inlet apertures 2262 in the outer body2214 of the control body 2202 and travel through a mounting plateaperture 2261 defined in the mounting plate 2219 and through and/oraround the combined dispenser and atomizer assembly 2218. The combinedair and aerosol may thereby be directed through a coupler aperture 2267defined in the coupler 2212, a base aperture 2263 defined in the base2216, and through an aerosol delivery aperture 2265 defined in the outerbody 2226 (or between the reservoir and the outer body) to themouthpiece 2224.

Further, FIG. 30 illustrates an alternate embodiment of an aerosoldelivery device 2300 wherein a combined dispenser and atomizer assemblyis positioned in a separate dispenser and atomizer body. As illustrated,the aerosol delivery device 2200 may include a control body 2302, adispenser and atomizer cartridge 2303, and a reservoir cartridge 2304,which are illustrated in a decoupled configuration. In this regard, abase 2316 of the reservoir cartridge 2304 may be configured to engage acoupler 2364 of the dispenser and atomizer cartridge 2303, and a base2366 of the dispenser and atomizer cartridge may be configured to engagea coupler 2312 of the control body 2302 to form mechanical andelectrical connections therebetween, which may be releasable to allowfor replacement of the dispenser and atomizer cartridge and/or thereservoir cartridge.

The control body 2302 may include an end cap 2306, a circuit board withan indicator 2308 (e.g., a light emitting diode (LED)), a connectorcircuit 2309, an electrical power source 2310 (e.g., a battery, whichmay be rechargeable), a flow sensor 2311 (e.g., a puff sensor orpressure switch), the coupler 2312, and wiring 2313. The dispenser andatomizer cartridge 2303 may include an outer body 2371, the base 2366,the coupler 2364, and a combined dispenser and atomizer assembly 2318.As illustrated, in one embodiment the combined dispenser and atomizerassembly 2318 may be positioned between, and coupled to, the base 2366and the coupler 2364. In particular, the combined dispenser and atomizerassembly 2318 may include a bubble jet head 2350 and an atomizer 2352,which may be connected via a flexible circuit 2353. In one embodimentthe bubble jet head 2350 may be mounted to the coupler 2364 and theatomizer 2352 may be mounted to the base 2366 of the dispenser andatomizer cartridge 2303.

The reservoir cartridge 2304 may include the base 2316, a reservoir2320, a lid 2322 that encloses the reservoir, a mouthpiece 2324, and anouter body 2326. When the reservoir cartridge 2304 is coupled to thedispenser and atomizer cartridge 2303, the reservoir 2320 may be influid communication with the bubble jet head 2350. In this regard, thereservoir 2320 may define an outlet 2356. In some embodiments the base2316 of the reservoir cartridge 2304 may also define an outlet 2358 thatmay align with the outlet 2356 to the reservoir. One or both of theoutlets 2356, 2358 may be initially sealed to retain an aerosolprecursor composition in the reservoir 2320. In this regard, by way ofexample, a foil or plastic seal may cover the outlets 2356, 2358.However, the seal may be broken (e.g., by piercing the seal) when thebase 2316 of the reservoir cartridge 2304 is engaged with the coupler2364 of the dispenser and atomizer cartridge 2303. Thereby, bypositioning the bubble jet head 2350 in proximity to the coupler 2364 ofthe dispenser and atomizer cartridge 2303, the bubble jet head mayreceive the aerosol precursor composition transferred from the reservoir2320 through the outlets 2356, 2358 and through an inlet 2360 at thecoupler of the dispenser and atomizer assembly. Thereby, the bubble jethead 2350 may dispense the aerosol precursor composition to the atomizer2352 to produce an aerosol.

A flow of air may enter through one or more inlet apertures 2362 in theouter body 2314 of the control body 2302 and thereby be directed throughat least one coupler aperture 2361 defined in the coupler 2312 of thecontrol body, at least one base aperture 2363 defined in the base 2366and through and/or around the aerosol dispenser and atomizer assembly2318. The combined air and aerosol may then travel through a coupleraperture 2365 defined in the coupler 2364 of the dispenser and atomizercartridge 2303, through a base aperture 2367 defined in the base 2316 ofthe reservoir cartridge 2304, through a vapor delivery aperture 2369defined in the outer body 2326 of the reservoir cartridge (or betweenthe reservoir and the outer body) to the mouthpiece 2324.

Accordingly, various alternative positional configurations may beemployed for the components of the aerosol delivery devices discussedherein. As noted above, in one embodiment the combined dispenser andatomizer assembly may be positioned in the control body (see, e.g., FIG.29). This configuration may be desirable in that the combined dispenserand atomizer assembly may have a usable life that exceeds that of thereservoir. However, in another embodiment the combined dispenser andatomizer assembly may be received in a separate dispenser and atomizercartridge (see, e.g., FIG. 30). This configuration may be desirable inthat although the combined dispenser and atomizer may have a usable lifethat exceeds that of the reservoir, the usable life of the combineddispenser and atomizer assembly may be less than that of the powersource and other components of the control body, or vice versa. Further,this configuration may allow for substitution of alternate embodimentsof combined dispensers and atomizer assemblies or control bodies toallow for customization of the aerosol delivery device to suit a userpreferences (e.g., by employing a bubble jet head configured to producea larger or smaller quantity of aerosol with each puff or by employing acontrol body with a larger battery).

In embodiments of aerosol delivery devices including a bubble jet head,the bubble jet head has generally been described as being fixedlycoupled to the atomizer that vaporizes the aerosol precursorcomposition. For example, in one embodiment (see, e.g., FIGS. 2-6) thebubble jet head is coupled to the atomizer via spacers. In anotherembodiment (see, e.g., FIGS. 7-11), the bubble jet head is fixedlycoupled to the atomizer via a shared housing. In an additionalembodiment the bubble jet head is coupled to the atomizer via a flexiblecircuit and one or both of the atomizer and the bubble jet head iscoupled to structure surrounding the combined dispenser and atomizerassembly (see, e.g., FIGS. 12-15). However, in another embodiment thebubble jet head may be decoupled from and aligned with the atomizer.Thereby, the space between the bubble jet head and the atomizer may beadjusted for the particular design of the bubble jet head, the viscosityof the aerosol precursor composition, and various other factors.

Further, in some embodiments the atomizer and/or the bubble jet head maybe configured to perform a cleaning cycle (e.g., by producing heat toremove aerosol precursor composition residue therefrom) eitherautomatically (e.g., after a specified number of users) or manually whenso directed by a user. This may be particularly useful in embodiments inwhich the bubble jet head and/or the atomizer is positioned in thecontrol body or a dispenser and atomizer cartridge and hence configuredfor reuse with multiple reservoirs.

The aerosol delivery devices described herein may avoid certain issuesassociated with conventional aerosol delivery devices that employ a wickto direct an aerosol precursor composition to an atomizer. In thisregard, use of a wick may cause separation of the ingredients of anaerosol precursor composition. Further, use of a wick to transfer theaerosol precursor composition from a substrate to a heating element mayresult in leakage. Accordingly, the embodiments of the aerosol deliverydevices disclosed herein may provide these and/or other advantages,including the advantages described above regarding greater control overthe dispensed quantity of aerosol precursor composition. Additionally,the bubble jet heads and the atomizers described herein may require lessenergy to dispense and atomize an aerosol precursor composition thanother embodiments of fluid delivery and vaporization mechanisms.Further, usage of a bubble jet head may allow for customization thereof(e.g., at the factory or by an end user). For example, the frequencyand/or duration of dispensing by the bubble jet head may be adjusted tomatch a user's preferences. Thereby, for example, the aerosol deliverydevice may be configured to vaporize a relatively smaller or largerquantity of aerosol precursor composition with each puff on the aerosoldelivery device, and such changes may be made without requiring a changein the hardware of the aerosol delivery device. In this regard, suchchanges may be implemented by software, or a change of electronicsettings.

Note that while the aerosol delivery devices disclosed herein aregenerally described as including a cartridge (e.g., a replaceablecartridge) and a control body (e.g., a reusable control body), variousother embodiments may be employed. For example, in other embodiments theaerosol delivery devices may include more than two-pieces, (e.g., asdescribed above with reference to FIG. 30). In an additional embodimentthe aerosol delivery device may define an integral, one-piececonfiguration. Thus, any of the aerosol delivery devices disclosedherein may be configured in any of a variety of manners in one or moreouter bodies.

Various embodiments of atomizers and vaporization heating elements aredescribed herein. As may be understood, various other embodiments ofatomizers and vaporization heating elements may be employed in otherembodiments. By way of example, in some embodiments the atomizer maycomprise a coil heater, which may receive an aerosol precursorcomposition dispense by a bubble jet head.

Further, the particular configuration of the bubble jet head relative tothe atomizer may vary. For example, in one embodiment a combineddispenser and atomizer assembly may include a housing with a firstchannel extending therethrough. The bubble jet head and the atomizer maybe coupled to opposing sides of the first channel such that the bubblejet head may dispense an aerosol precursor composition onto theatomizer. For example, a second channel defined in the housing maysupply the aerosol precursor composition to the bubble jet head. Theresultant vapor may exit the housing via the first channel in which thebubble jet head and the atomizer are received.

In an additional embodiment, a method for aerosolization in an aerosoldelivery device is provided. As illustrated in FIG. 31, the method mayinclude directing an airflow from a control body comprising a powersource through a cartridge comprising a reservoir at operation 2402.Further, the method may include dispensing an aerosol precursorcomposition from the reservoir via a bubble jet head at operation 2404.The method may additionally include heating the aerosol precursorcomposition dispensed from the reservoir by the bubble jet head with anatomizer at operation 2406.

In some embodiments of the method dispensing the aerosol precursorcomposition at operation 2404 and heating the aerosol precursorcomposition at operation 2406 comprise independently applying power fromthe power source to the bubble jet head and the atomizer. Further,dispensing the aerosol precursor composition at operation 2404 andheating the aerosol precursor composition at operation 2406 may comprisedirecting power to the atomizer after applying power to the bubble jethead. The method may further comprise preheating the aerosol precursorcomposition with the bubble jet head prior to dispensing the aerosolprecursor composition at operation 2406. Additionally, the method mayinclude detecting a temperature of the aerosol precursor composition,wherein preheating the aerosol precursor composition comprisespreheating the aerosol precursor composition to a desired temperature.Preheating the aerosol precursor composition may comprise applying arelatively smaller pulse width of power to the bubble jet head ascompared to dispensing the aerosol precursor composition.

Many modifications and other embodiments of the disclosure will come tomind to one skilled in the art to which this disclosure pertains havingthe benefit of the teachings presented in the foregoing descriptions andthe associated drawings. Therefore, it is to be understood that thedisclosure is not to be limited to the specific embodiments disclosedherein and that modifications and other embodiments are intended to beincluded within the scope of the appended claims. Although specificterms are employed herein, they are used in a generic and descriptivesense only and not for purposes of limitation.

What is claimed is:
 1. An aerosol delivery device, comprising: areservoir at least partially filled with an aerosol precursorcomposition; a bubble jet head comprising a precursor inlet and aprecursor nozzle in fluid communication with the reservoir, the bubblejet head being configured to dispense the aerosol precursor compositionfrom the reservoir; an atomizer comprising an aerosol outlet andconfigured to heat the aerosol precursor composition dispensed by thebubble jet head to produce an aerosol; a housing arranged within theaerosol delivery device and defining at least one of the precursorinlets, the precursor nozzle, and the aerosol outlet, wherein theaerosol precursor composition is initially prevented from traveling toat least one of the atomizer and the bubble jet head, and wherein, inresponse to an input to the aerosol deliver device, the aerosol deliverydevice is configured to permit traveling of the aerosol precursorcomposition toward the atomizer and/or bubble jet head, and wherein thepressure within the reservoir is negative, wherein the negative pressureacts to resist passive travel of the aerosol precursor composition outof the reservoir.
 2. The aerosol delivery device of claim 1, wherein thebubble jet head comprises a precursor nozzle, and wherein the precursornozzle is sized so as to resist travel therethrough of the aerosolprecursor composition such that the aerosol precursor composition isinitially prevented from traveling to the atomizer.
 3. The aerosoldelivery device of claim 1, wherein the bubble jet head comprises aplurality of precursor nozzles, and wherein the plurality of precursornozzles are sized so as to resist travel therethrough of the aerosolprecursor composition such that the aerosol precursor composition isinitially prevented from traveling to the atomizer.
 4. The aerosoldelivery device of claim 1, wherein the negative pressure is applied tothe reservoir prior to sealing the reservoir shut so as to provide thenegative pressure within the reservoir.
 5. The aerosol delivery deviceof claim 1, further comprising a flow sensor, and wherein the input isan input indicative of a user's puff detected by the flow sensor.
 6. Theaerosol delivery device of claim 1, wherein, in response to the input,the aerosol delivery device is configured to eject the aerosol precursorcomposition towards the atomizer.
 7. The aerosol delivery device ofclaim 6, wherein the bubble jet head further comprises one or moreejection heating elements, and in response to the input, the aerosoldelivery device is configured to supply current to the one or moreejection heating elements.
 8. The aerosol delivery device of claim 1,wherein the bubble jet head is configured to eject the aerosol precursorcomposition substantially perpendicularly to a heating surface of theatomizer.
 9. The aerosol delivery device of claim 1, wherein a heatingsurface of the atomizer is non-planar.
 10. The aerosol delivery deviceof claim 1, wherein a heating surface of the atomizer is textured. 11.The aerosol delivery device of claim 1, wherein the reservoir comprisesa reservoir substrate configured to direct the aerosol precursorcomposition to the bubble jet head.
 12. The aerosol delivery device ofclaim 1, wherein the bubble jet head is coupled to a distal end of thereservoir.
 13. The aerosol delivery device of claim 1, wherein thebubble jet head is coupled to a lateral side of the reservoir.
 14. Theaerosol delivery device of claim 1, wherein the bubble jet head and theatomizer are positioned between the reservoir and a mouthpiece.
 15. Theaerosol delivery device of claim 1, wherein the reservoir is positionedbetween a mouthpiece and the atomizer and the bubble jet head.
 16. Theaerosol delivery device of claim 1, wherein the bubble jet headcomprises an ejection heating element and the atomizer comprises avaporization heating element.
 17. The aerosol delivery device of claim16, wherein a thermal mass of the ejection heating element is less thana thermal mass of the vaporization heating element.
 18. The aerosoldelivery device of claim 1, wherein an area of the aerosol outlet isgreater than an area of the precursor nozzle.
 19. The aerosol deliverydevice of claim 1, wherein the ejection heating element, the precursornozzle, and the vaporization heating element are axially aligned.